&EPA
United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
EPA-600/7-80-010a
January 1980
Coal Preparation Plant
Computer Model:
Volume I.
User Documentation
Interagency
Energy/Environment
R&D Program Report
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EPA-600/7-80-010a
January 1980
Coal Preparation Plant Computer Model
Volume I.
User Documentation
by
Frederick K. Goodman and Jane H. McCreery
Battelle Memorial Institute
Columbus Laboratories
505 King Avenue
Columbus, Ohio 43201
Contract No. 68-02-2163
Task No. 814
Program Element No. EHE623A
EPA Project Officer: James D. Kilgroe
Industrial Environmental Research Laboratory
Office of Environmental Engineering and Technology
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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FOREWORD
Many elements and chemical compounds are known to be toxic to man
and other biological species. But our knowledge concerning the levels and
conditions under which these substances are toxic is extremely limited.
Further, little is known concerning the emission of these pollutants from
industrial processes and the mechanism by which they are transported, trans-
formed, dispersed, or accumulated in our environment.
Portions of the Federal Clean Air Act, the Resource Conservation
Recovery Act, and the Federal Water Pollution Control Act require the U.S.
Environmental Protection Agency (EPA) to identify and regulate hazardous or
toxic substances which result from man's industrial activities. Industrial
pollutants are often identified only after harmful health or ecological
effects are noted. Remedial actions are costly, the damage to human and
other biological populations is often irreversible, and the persistence of
some environmental contaminants may endanger future populations.
EPA's Office of Research and Development is responsible for health
and ecological research, studies concerning the transportation and fate of
pollutants, and the development of technologies for controlling industrial
pollutants. As a part of this office, the Industrial Environmental Research
Laboratory, which is responsible for development of pollution control techno-
logy, conducts a large environmental assessment program. The primary objectives
of this program are:
• The development of information on the quantities of
toxic pollutants emitted from various industrial
processes—information needed to prioritize health
and ecological research efforts.
• The identification of industrial pollutant emissions
which pose a clearly evident health or ecological risk
and which should be regulated.
• The evaluation and development of technologies for
controlling pollution from these toxic substances.
The coal cleaning environmental assessment program has as its
specific objectives the evaluation of pollution and pollution control problems
which are unique to coal preparation, storage, and transportation. The coal
preparation industry is a mature yet changing industry, and in recent years
significant achievements have been made in pollution abatement. As an aid
in the evaluation of an advanced physical coal cleaning facility being
constructed near Homer City; Pennsylvania, an existing computer program
was verified and modified to simulate the design and operation of physical
coal preparation plants. Specifically, this report provides user documentation
(Volume I) and programmer documentation (Volume II) for Coal Preparation
Simulation Model Version 4 (CPSM4) as modified by Battelle.
11
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PREFACE
Since July, 1976, Battelle's Columbus Laboratories has been con-
ducting a major study for the U.S. EPA on the environmental assessment of
coal cleaning processes. In one portion of this study, existing computer
programs capable of modeling coal preparation plants were verified and modi-
fied to aid in the evaluation of an advanced coal cleaning facility being con-
structed at Homer City, Pennsylvania. The only computer program found with the
required capabilities was one developed in FORTRAN under the technical leader-
ship of the U.S. Bureau of Mines and the sponsorship of the U.S. EPA. The
original version of this program, Coal Preparation Stimulation Model Version 4
(CPSM4) is described in Gottfried, Jacobsen, and Vaillant .
This document describes in detail a Battelle modified program
CPSM4. The Battelle version of CPSM4 maintains all of the basic capabilities
of the original version; however, these have been restructured and augmented
extensively to make the program usable in the evaluation of a particular
plant.
The actual presentation is divided into two volumes: the first
contains user documentation and the second contains program documentation. The
goal of the first volume is to make the program a usable and understandable
tool for the nonprogrammer interested in the simulation of coal preparation
plants. The second volume is intended for individuals with knowledge of the
FORTRAN language who are interested in the detailed implementation of the
material presented in Volume I.
* Reference numbers refer to the Reference List at the end of Volume I.
separate reference list is included at the end of Volume II.
111
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Although pages in each volume are numbered sequentially, tables
and figures are numbered by volume, chapter, and part followed by a sequence
number as shown below. The numbering of equations begins at (1) within
each part.
II-12-6.2
I
i
part
chapter
volume
sequence number
IV
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ABSTRACT
This report documents a steady state modeling system that simulates
the performance of coal preparation plants. This modeling system was devel-
oped originally under the technical leadership of the U.S. Bureau of Mines
and the sponsorship of the U.S. Environmental Protection Agency. The
modified form described in this report was developed by Battelle for the
U.S. Environmental Protection Agency. The system is written in FORTRAN.
The original purpose of the modifications was to make the program
usable in the evaluation of an advanced coal cleaning facility being constructed
at Homer City, Pennsylvania. Subsequent changes were made to allow the model
to be used for a wider range of performance and cost evaluations. Initial
changes to the original program were made to (1) increase the number of
process operations which could be similated and (2) simplify operation of
the program. Later modifications were made to permit the calculation of
plant water flows and the estimation of plant costs.
The report is divided into two volumes; Volume I contains user
documentation, and Volume II provides program documentation. The manner
in which flows of coal are represented and the mathematical approach of the
various unit operations are discussed in detail in Volume I. Also, the
approach taken for the evaluation of costs is presented. The preparation
of the input and the interpretation of the output are described in terms
of an example. In Volume II, the program documentation begins with a
discussion of the basic principles of documentation and then presents each
routine and common block in the system in terms of these principles.
This report covers work during the period from July 1976 through
July 1979.
v
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TABLE OF CONTENTS
(Volume I)
FOREWORD
PREFACE
ABSTRACT
LIST OF FIGURES
LIST OF TABLES
ACKNOWLEDGEMENTS
1.0 INTRODUCTION
1.1 Conclusions 4
1.2 Recommendations 5
2.0 OVERVIEW
2.1 A Physical Simulation Example 8
2.2 Cost Component Example 13
3.0 REPRESENTATION OF FLOWS 20
3.1 The Uniformity Assumption 22
3.2 Classifying Unit Operations 25
3.3 Retreatment Flows 26
4.0 THE UNIT OPERATIONS 28
4.1 Blending 29
4.2 Splitting 33
4.3 Screening 35
4.4 Washing 43
4.4.1 Generalized Distribution Curves 46
4.4.2 C-Generalized Distribution Curves 49
4.5 Two-Stage Washing 57
4.6 Froth Flotation 61
4.7 Resizing Unit Operations 65
4.7.1 Liberation 65
4.7.2 Breakage and Selection for Breakage 66
4.7.3 Screening 67
4.7.4 Prebreakage 67
4.8 Rotary Breaking 69
4.9 Crushing 7^
4.10 Dewatering 73
vi
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TABLE OF CONTENTS
(Continued)
Page
5.0 THE COMPUTATION OF COST 74
5.0.1 An Example Project to be Costed 77
5.1 Measuring Profitability 78
5.1.1 The Project Cash Flow Description 78
5.2 The Discounted Cash Flow Analysis 81
5.2.1 Basic Identities Used 81
5.2.2 The Actual Procedure 83
6.0 PREPARING THE INPUT 85
6.1 General Coding Conventions 87
6.2 The Equipment Inventory 90
6.3 Coding the Equipment Inventory 93
6.3.1 Equipment Inventory Count Card 93
6.3.2 Equipment Type Definition Card 104
6.3.3 Coding Splitting and Blending Equipment .... 105
6.3.4 Coding Washing Equipment 105
6.3.5 Coding Two-Stage Washing Equipment 108
6.3.6 Coding Froth Flotation Equipment 109
6.3.7 Coding Screening Equipment 109
6.3.8 Coding Rotary Breaking Equipment 110
6.3.9 Coding Crushing Equipment Ill
6.3.10 Coding Prebreakage Information . Ill
6.4 Defining the Configuration 112
6.5 Coding the Configuration 117
6.6 Coding the Feed 120
6.7 Configuration and Feed Selection 128
6.8 The Run Control 131
6.9 The Cost Component 132
7.0 -INTERPRETING THE OUTPUT 137
7.1 The Units Input Report 138
7.2 The Flows Input Report 139
7.3 The Flowstream Specific Gravity Analysis Report . . . 140
7.4 The Unit Performance Characteristics Report 141
VII
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TABLE OF CONTENTS
(Continued)
Page
7.4.1 The General Characterization 142
7.4.2 Screening Measures 143
7.4.3 Washing Measures 144
7.4.4 Rotary Breaking Measures 149
7.-5 Summary Data for Units Reports 150
7.6 Summary Data for Flowstreams Report 15^
8.0 REFERENCE LIST FOR VOLUME I 152
APPENDIX A USER HANDBOOK EXAMPLE 153
APPENDIX B USER HANDBOOK COST EXAMPLE 223
vxn
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LIST OF FIGURES
Figure No. Page
I-1-0.1 Unit Operations Simulated 3
1-2-1.1 Example of Plant Configuration 10
1-2-2.1 Cost Component Example - Jig Process -
Simple Preparation Plant Flow Sheet 14
1-3-1.1 Direct Percent Ash 23
1-4-3.1 Adjustment Factors for Screening 37
1-4-4.1 Typical Distribution Curve 45
1-6-2.1 The Generalized Equipment Inventory 92
1-6-3.1 Field Descriptions for Coding Equipment Inventory ... 94
1-6-3.2 Listing of Equipment Inventory Segment for
User Handbook Example 97
1-6-4.1 Decision Variables 113
1-6-4.2 Flowstream Type Codes 114
1-6-4.3 Unit Operation Flow Type Association 115
1-6-4.4 Configuration of User Handbook Example 116
1-6-5.1 Field Descriptions for Configuration 118
1-6-5.2 Listing of Configuration Specification 119
1-6-6.1 Field Descriptions for Specifying Feed 121
1-6-6.2 Input Listing for Feed 126
1-6-7.1 Field Descriptions for Configuration and
Feed Selection 129
1-6-7.2 Input Listing for Configuration and Feed Selection . . 130
1-6-8.1 Field Specification for Run Control .... 131
1-6-9.1 Field Descriptions for Coding Cost Component ..... 133
1-6-9.2 Input Deck for User Handbook Cost Example ....... 136
IX
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Table No.
LIST OF TABLES
Page
1-2-1.1 Specific Gravity Analysis of the Size Fractions
and Composite Feed to the Preparation Plant 11
1-2-2.1 Cost Component Example - Jig Process - Simple
Washability Data of Assumed Plant Feed 15
1-2-2.2 Cost Component Example - Jig Process - Simple
Preparation Plant Capital Requirements 17
1-2-2.3 Cost Component Example - Jig Process - Simple
Operating and Maintenance Costs 19
1-4-3.1 Adjustment Factors for Screening 35
1-4-4.1 Distribution Curves and Generalized Distribution Curves
for 1/4 inch by 8 mesh Size Fraction for Dense
Medium Cyclone Washers 47
1-4-4.2 C-Generalized Curve Data for Concentrating Table
by Size Fraction 52
1-4-4.3 C-Generalized Curve Data for Dense Medium Vessel by
Size Fraction 53
1-4-4.4 C-Generalized Curve Data for Dense Medium Cyclone
by Size Fraction 54
1-4-4.5 C-Generalized Curve Data for Hydro Cyclone by
Size Fraction 55
1-4-4.6 C-Generalized Curve Data for Single-stage Baum
Jig by Size Fraction 56
1-4-5.1 C-Generalized Middling Curve Data for Two-Stage
Baum Jig by Size Fraction 59
1-4-6.1 Raw Generalized Distribution Curves Used for
Froth Flotation Unit Operation 64
1-4-9.1 Crusher Breakage Distribution 72
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ACKNOWLEDGEMENTS
This study-was conducted as a Task on Battalia's Columbus Laboratories'
program "Environmental Assessment of Coal Cleaning Processes" supported by the
Industrial Environmental Research Laboratory, U.S. Environmental Protection Agency,
Research Triangle Park, North Carolina.
Dr. Byron S. Gottfried, Departments of Industrial Engineering and
Energy Resources at the University of Pittsburgh, and P. Stanley Jacobsen,
Coal Preparation and Analysis Laboratory of the U.S. Bureau of Mines, are
thanked for their patient assistance. Valuable assistance has been provided,
through comments in several progress review meetings, by Mr. Ed Zawadzki, con-
sultant to General Public Utilities Corporation, Messrs. Charles Statler, Ray
McGraw, and Jim Tice of Pennsylvania Electric Company, Dr. Gerald Janik of
New York State Electric and Gas Corporation, and Mr. Ken Harrison of Heyl and
Patterson, Inc.
The contributions of Mr. G. Ray Smithson, Jr., Program Manager,
Mr. Alexis W. Lemmon, Jr., Deputy Program Manager, and Dr. Gerald L. Robinson,
Task Leader, are gratefully acknowledged.
The advice, counsel, and comments of the EPA Project Officer, Mr.
James D. Kilgroe, and others at the IERL/RTP facility were invaluable in
performance of this work.
XI
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I USER HANDBOOK
1.0 INTRODUCTION
The computer program described in this document resulted from a
modeling effort related to existing software in the area of coal preparation
simulation. The original purpose was to review and modify this software to
aid in the evaluation of an advanced coal cleaning facility being constructed
at Homer City, Pennsylvania. The resulting computer program described here
more than satisfies this goal in that it is not restricted to simulating
the Homer City coal preparation plant; it is able to simulate coal prepara-
tion plants in general. Four computer programs were surveyed:
(1) A coal preparation plant simulation model (CPSM4),
described in Gottfried, Jacobsen, and Vaillant
(2) A program to perform complete coal washability and froth
flotation calculations and to automatically plot all
washability curves, described in Humphreys, Leonard,
(2)
and Buttermore
(3) Coal cleaning programs designed by PEDCo-Environmental,
(3)
described in Isaacs
(4) A computer simulation model for coal preparation plant
(4)
design and control, described in Walter
Each of these programs contained unique features which hopefully
will be available at some future date in a single program. However, only the
coal preparation plant simulation model was sufficiently flexible to be
directly usable in the evaluation of the Homer City Plant. This program was,
therefore, selected for modification.
The original purpose for the modeling effort directed by the U.S.
Bureau of Mines that resulted in the construction of program CPSM4 was to give
the user the ability to simulate "the performance of ... configurations
representative of actual preparation plants". The key word in the above
purpose is representative. The program was not originally designed to
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simulate actual plant conditions. Rather its role was to give users the
ability to examine a representative picture of some configuration as it
might impact on a given type of coal. Such analysis is important and
valuable for the various design tasks which might precede the actual
construction of a plant or, more importantly, which might precede the
very decision to build a plant.
With this purpose in mind, the authors of the program made every
effort to derive algorithms and generalized coefficients which would
adequately represent the behavior of the various types of equipment listed
in Figure I-1-0.1. These algorithms included generalized distributed curves,
classification functions, selection for breakage functions, breakage distri-
butions, and others, all of which will be discussed in detail in Chapter 1-04.
This work was very well formulated and programmed in the original version
of the program. It is a major asset to the design effort and all of
it has been maintained in the present version of the program, though in
slightly different form.
The goal of this research effort was not to simulate a representa-
tive configuration; rather it was to simulate a particular plant—the Homer
City plant. Actual design curves describing the expected performance of units
of equipment in the plant were available. Eventually, actual performance
curves also will be available when the plant becomes operational. The
goal set for the program was to generate results which agreed as closely as
possible with the material balance prepared by the design team for the plant.
To achieve this goal, it was necessary to modify the program to deal not just
with generalized descriptions of equipment behavior but also with particular
descriptions—those used by the designers in preparing the material balance.
This basic modification was the purpose of the modeling effort which resulted
in the version of CPSM4 described herein.
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Unit Operation
Blending
Splitting
Screening
Single-stage washing
Two-stage washing
Froth flotation
Ro'tary breaking
Crushing
Dewatering
Equipment Type
Stream blender
Stream splitter
Dry upper screen
Dry lower screen
Wet upper screen
Wet lower screen
Concentrating table
Dense medium vessel
Dense medium cyclone
Hydrocyclone
Single-stage Baum jig
Classifying cyclone
Two-stage Baum jig
Froth flotation cell
Rotary breaker
Primary multiple roll crusher
Primary gyratory/jaw crusher
Primary single roll crusher
Primary cage mill crusher
Secondary multiple roll crusher
Secondary gyratory/jaw crusher
Secondary single roll crusher
Secondary cage mill crusher
Centrifuge
Dryer
FIGURE 1-1-0.1. UNIT OPERATIONS SIMULATED
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1.1 Conclusions
The major purpose of this effort was to modify program CPSM4 so that
it could be used in the evaluation of an actual coal cleaning plant. In this
context the term could be used was taken to have two levels of meaning. In
one sense, it was assumed that the program could be used for a particular
plant only if it could reproduce the performance, or expected performance, of
that plant. In this sense the utility of the program is measured in terms
of its predictive ability. In the other sense, it was assumed that the program
could be used for a particular plant only if the personnel associated with that
plant felt that they understood the mathematics of-the simulation and knew how
to control it. The point here is that no matter what the predictive ability
of a program might be, it will not be used if the staff who require its use
either cannot control it or do not understand it.
That the program is now able to produce plant performance predic-
tions in agreement with design predictions, given equipment performance
data, has been demonstrated in the Homer City application. Actual perfor-
mance data was not available for comparison. The process modeling approach
seems ideally suited to the simulation of coal preparation plants. In this
sense, the purpose of the effort has been achieved, at least from the
design standpoint.
From the other standpoint, the facts are not yet clear. There are
currently plans underway to distribute the program and this document to many
users. After that has been done, conclusions on its utility can be drawn.
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1.2 Recommendations
There are two general recommendations to be made. In the first
place there are currently two versions of the program in use, which do not
produce the same results. The different results stem from two services:
(1) An error was found in the code for the rotary
breaker unit operation in the original version
of CPSM4; this has been corrected in the present
version of the program.
(2) For a two-stage Baum jig, the particular C-generalized
distribution curves used within the program give
slightly different results than the generalized
distribution curves used in the original version
of CPSM4; this difference arises from a recalibration
of the curves done in the present version of the
program.
To avoid confusion and misunderstanding, these differences should be removed.
Some compromise may be needed to accomplish this. The versions have different
objectives and need not be structured in the same way; however, they should
produce the same result when presented with the same problem.
The other recommendation is that the program be used as widely as
possible in as many different situations as possible. This use will almost
certainly lead to the discovery of problems both with the program and with
this documentation, which would then have to be corrected. It is only in
this way, however, that a truly useful tool can be developed.
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2.0 OVERVIEW
Program CPSM4 is a computer program which simulates certain aspects
of the performance of a coal preparation plant. Generically," it is-*a steady-
state processing modeling system. The term process refers to the fact that
CPSM4 views a coal preparation plant as consisting "of'a set of£ components, or
units of equipment interconnected via a set of flows of coal which they
manipulate. The term steady-state refers'to the assumption made within CPSM4
that the characterizations of neither the behavior af the unit operations nor
the flows vary as a function of time. The formalization of a 'coal preparation
plant as a process is ideal. The steady-state assumption is clearly a
reasonable but simplifying one. No attempt will be made in this presentation
to justify this methodological approach to the simulation of a coal prepa-
ration plant. It is taken as given.
The program, then, considers a coal preparation plant to be composed
of a set of discrete interconnected units which perform operations on the
flow of coal. The term unit operation refers to the mathematical operation
used to simulate a given equipment type. Figure 1-1-0.1 shows the particular
types of unit operations presently included along with a list of the actual
equipment types simulated using those unit operations.
The use of program CPSM4 requires three-types of ".information: first,
a float-sink type specific gravity analysis of the coal to be processed;
second, a configuration showing the units of equipment as they are to?be
applied to the coal; and third, an equipment inventory describing the perfor-
mance of each equipment type relative to the unit operations. The. program
will then produce an analysis of the performance of each unit of equipment, a
specific gravity analysis of each output flow from each unit, a summary of the
unit performances, and a summary of the flow characteristics. The purpose of
this volume is to describe user preparation of input for the program, the
mathematical operations which the program performs on those inputs, and the
meanings of the resultant outputs. This presentation assumes that the reader
is familiar with the physical processes and equipment types involved in coal
preparation.
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To simplify the discussion throughout this volume, two examples are
presented here. The first example emphasizes the physical simulation capabil-
ities of CPSM4, while the second emphasizes the cost calculation capabilities,
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2.1 A Physical Simulation Example
The physical simulation example was obtained from Gottfried, Jacobsen,
and Vaillant^ ' and modified to allow the inclusion of water flowstreams,
retreatment flowstreams, and centrifuges. Figure 1-2-1.1 shows a typical plant
configuration which includes all of the general types of equipment which can
be treated by the program except a stream splitter. However, since a centrifuge
is modeled as a splitter with breakage, splitters are implicitly included in
the plant configuration. Table 1-2-1.1 shows the specific gravity analysis of
the size fractions and composite feed to the plant. As mentioned, these two
types of information are required to use the program.
The plant configuration is as follows. The feed, which is 18 inches
by 325 mesh in size, enters a rotary breaker whose drum is 20 feet long, 12 feet
in diameter, and has an opening size of 6 inches. The refuse from the breaker
is sent to a refuse stream. The underflow from the breaker, which is 6 inches
by 325 mesh, is sent to a wet double deck screen. The upper deck has a mesh
size of 1-1/3 inches, while the lower has a size of 1/2 inch. The overflow
from the double deck screen, which is 6 inches by 1/2 inch, goes to a two-stage
baum jig with a specific gravity of separation of 1.62. The clean coal output
from the baum jig goes to the clean output of the plant. The refuse from the
baum jig is blended with the refuse from the rotary breaker. The middling
output of the jig is sent to a secondary multiple roll crusher. This crusher
has a setting of 0.28 inches. The crushed coal produced here is blended with
the underflow of the wet double deck screen. The blended coal then passes
through a set single deck screen with a 28 mesh size. The overflow of this
screen is cleaned by a concentrating table with a specific gravity of separ-
ation of 1.58. The refuse from this table is sent to the refuse stream while
the clean is blended into the clean output flow.' The underflow from the
single deck screen goes to a froth flotation cell whose refuse and clean output
are treated appropriately. Finally, both the clean and refuse output flows
are passed through centrifuges to dewater the flows.
8
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A detailed washability analysis, shown in Table 1-2-3.1, is provided
for the feed stream to the plant. Note that no information is provided for
the minus 325 mesh material. It is assumed, therefore, in the program and in
the configuration that no minus 325 mesh material is present in any of the
flows.
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Rotary Breaker
18"x325m
FEED
Wet double
deck screen
18"x325m
6"xl/2
\ V
s \
Two-stage baum jig
0=1.62
Secondary multiple
roll crusher
l/2"x325m
Wet single
deck screen
l/2"x28 mesh
Froth flotation
cell
Concentrating
table
P=1.58
28mx325m
Centrifuge; \
Centrifuge
CLEAN COAL
EFUSE
FIGURE 1-2-1.1. EXAMPLE OF PLANT CONFIGURATIONS
10
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TABLE 1-2-1.1. SPECIFIC GRAVITY ANALYSIS OF THE SIZE FRACTIONS AND
COMPOSITE FEED TO THE PREPARATION PLANT
Size fraction
and weight
18 by 12 Inches
7.1 Percent
12 by 6 Inches
23.1 Percent
6 by 2 Inches
32.2 Percent
2 by 1/2 Inches
13.1 Percent
1/2 Inch by
8 Mesh
13.0 Percent
8 by 28 Mesh
5.6 Percent
28 by 100 Mesh
3.2 Percent
100 by 325 Mesh
2.6 Percent
Composite
100.0 Percent
Specific
gravity
Float 1.
1.30-1.
1.35-1.
1.40-1.
1. 50-1..
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
Float 1.
1.30-1.
1.35-1.
1.40-1.
1.50-1.
1.60-1.
1.70-1.
Sink-1.
30
35
40
50
60
70
80
80
30
35
40
50
60
70
80
80
30
35
40
50
60
70
80
80
30
35
40
50
60
70
30
80
30
35
40
50
60
70
80
80
30
35
40
50
60
70
80
80
30
35
40
50
60
70
80
80
30
35
40
50
60
70
80
80
30
35
40
50
60
70
80
80
Weight
19.7
11.0
2.1
11.3
2.1
1.9
.8
51.1
16.7
14.3
5.3
5.3
4.1
2.1
1.2
51.0
21.4
11.8
2.2
12.1
1.9
1.7
.7
48.1
22.0
19.9
6.9
7.5
4.5
2.2
1.6
35.3
33.5
23.1
7.5
6.9
3.2
1.8
1.5
22.5
48.0
19.5
5.8
4.9
2.3
1.4
1.1
17.0
59.0
12.5
8.5
4.2
2.0
1.0
.6
12.2
36.4
24.0
15.6
5.6
2.3
1.0
.5
14.7
25.0
15.7
5.0
8.4
3.0
1.8
1.1
40.2
Dl:
Ash
:.8
4.4
7.8
15.4
25.0
31.5
41.0
84.6
2.9
4. 7
9.4
16.7
26.7
35.1
45.7
82.9
2.8
4.4
7.8
15.3
24.9
31.5
41.0
84.6
2.4
4.7
9.6
16.1
25.9
34.1
42.3
82.6
2.4
4.8
9.7
15.7
25.7
33.8
41.4
84.2
1.8
4.3
8.8
15.4
24.4
33. 3
41.7
82.8
1.8
6.4
8.3
15.5
22.8
28.4
34.3
67.7
1.2
2.7
4.2
11.0
17.6
24.1
32.2
67.3
2.5
4.6
8.7
15.6
25.6
33.1
42.4
S3. 5
Pvri t ic
sulfur
.21
.71
.98
1.10
1.44
2.90
5.46
18.43
.18
.62
1.05
1.52
1.97
3.23
6.07
17.00
.13
.64
1.25
1.88
2.68
4.01
5.55
20.13
.14
.49
.95
1.41
2.05
3.51
5.56"
17.54
.08
.11
.45
.65
1.48
2.79
3.87
21.09
.20
.43
1.00
1.50
2.20
3.45
6.28
21.02
.16
.73
1.02
2.05
3.27
4.51
6.44
20.43
.10
.28
.41
1.14
2.38
4.09
7.44
26.50
.14
.49
.88
1.54
2.09
3.47
5.46
18.91
cent
Total
.79
1.57
1.59
1.60
1.84
3.50
6.13
19.23
.80
1.22
1.65
2.08
2.47
3.78
6.56
18.14
.80
1.32
1.85
2.49
3.25
4.66
6.30
20.98
.77
.99
1.40
1.95
2.49
3.97
6.04
20.02
.64
.69
.92
1.17
1.86
3.00
4.04
21.89
.68
.98
1.50
2.02
2.67
4.06
6.70
21.72
.73
1.24
1.49
2.63
3.73
5.17
7.22
21.41
.64
.84
1.01
1.66
2.98
4.32
8.06
26.50
.74
1.09
1.42
2.11
2.56
4.00
5.95
20.02
Cumulative, percent
Btu/lb
15335
14907
13909
12682
11077
9723
3269
1561
15355
14907
13909
12682
11077
9723
8269
1563
15355
14907
13909
12682
11077
9723
8269
1563
15355
14907
13909
12682
11077
9723
3269
1563
15355
14907
13909
12682
11077
9723
8269
1563
1535'
14907
13909
12682
11077
9723
8269
1563
15355
14907
13909
12682
11077
9723
8269
1563
15355
14907
13909
12682
11077
9723
8269
1563
15355
14907
13909
12682
11077
9723
8269
1:>63
Weight
19.7
30.7
J2.S
44.1
46.2
48.1
48.9
100.0
16.7
31.0
36.3
41.6
45.7
47.8
49.0
100.0
21.4
33.2
35.4
47.6
49.5
51.2
51.9
100.0
22.0
42.0
48.9
56.4
60.9
63.1
64.7
100.0
33.5
56.6
64.1
71.0
74.2
76.0
77.5
100.0
48.0
67.5
73.3
78.2
30.5
81.9
83.0
100.0
59.0
71.5
80.0
84.2
86.2
87.2
87.8
100.0
36.4
60. 3
75.9
81.5
83.8
84.8
85.3
100.0
25.0
40.6
45.6
54.0
57.0
58.8
59.8
100. 0
A s,h
2 . 8
3.4
3.7
5.7
7.5
8.4
9.0
47.6
2.9
3.7
4.6
6.1
8.0
9.1
10.0
47.2
2.8
3.4
3.6
6.6
7.3
8.1
8.6
45.1
2.4
3.5
4.4
5.9
7.4
8.3
9.2
35.1
2.4
3.4
4.1
5.2
6.1
6.8
7.5
24.7
1.8
2.5
3.0
3.8
4.4
4.9
5.4
18.5
1.8
2.6
3.2
3.8
4.3
4.5
4.7
12.4
1.2
1.8
2.3
2.9
3.3
3.5
3.7
13.0
2 . 5
3.3
3.9
5.7
6.7
7.5
3.2
38.4
I'yritic
sulfur
.21
. J9
.43
.60
.64
.73
.80
9.81
.18
. J8
.48
.hi
.73
.84
.97
9.14
.13
.31
.37
.76
.33
. 94
1.00
10.20
.14
.31
.40
.53
.65
.75
.86
6.75
.08
.09
.13
.18
.24
.30
.37
5.03
.20
.28
.34
.41
.46
.51
.59
4.06
.16
.26
.34
.43
.49
.54
.58
3.00
.10
.17
.22
.28
.34
.39
.43
4.12
.14
.28
.34
.53
.61
.70
.78
S.OL
Total
sulfur
.79
1.07
1.10
1.23
1.26
1. 35
1.42
10.52
.80
.99
1.09
1 . 22
1.33
1.44
1.56
10.01
.30
.99
1.04
1.41
1.48
1.59
1.65
10.95
. 77
.87
.95
1.08
1.19
1.28
1.40
7.97
.64
.61)
. 60
. 74
.79
.84
.90
5.62
.68
.77
.82
.90
.95
1.00
1.08
4.58
.73
.82
.39
.98
1.04
1.09
1.13
3.60
.64
.72
.78
.84
.90
.94
.98
4.73
.74
.88
.94
1.12
1.19
1.28
1. 36
a. so
Blu/lb
13335
15194
15112
14489
14334
14132
14056
7672
15355
15143
14967
14676
14333
14150
14006
7666
13355
13192
15115
14494
14362
14208
14127
8035
13355
13142
14968
14663
14398
14235
14087
9670
15355
15172
15024
14796
14635
14513
14397
11314
15355
15226
15121
14968
14856
14768
14682
12456
15355
15277
13131
15009
14918
14858
14813
13197
15355
15177
14917
14763
14662
14604
14567
12657
15355
15182
15043
14676
14438
14340
14232
9145
11
-------
The actual results of running the configuration against the feed
stream are given in Appendix A. The tables in this appendix will be
referred to often in the following discussion. They will be referenced as
The User Handbook Example.
12
-------
2.2 Cost Component Example
The source of the cost component example is Holt . It is a simple
jig process as shown in Figure 1-2-2.1. Table 1-2-2.1 shows the specific
gravity analysis of the feed to the plant.
The plant configuration is as follows.
From the raw coal storage area, the 8 inch by 0 material is conveyed
via a 42 inch wide belt to a 6 by 16 foot single deck vibrating screen. As
a result of the force of being dropped onto this screen and the vibrating
action, the larger pieces of coal are fractured to 6 inches or less. The
small amount of material which does not reduce to 6 inches or less passes
over the screen and reports to the refuse belt. The 600 tph of 6 inch by 0
raw coal is fed to an eight-cell three-compartment baum type jig. Of the
material entering the jig, 372 tph "floats" out and 234 tph sinks as refuse.
This refuse goes to a 5 by 10 foot double deck vibrating screen with 1/2 mm
openings in the bottom deck where it is partially dewatered before reporting
to the refuse belt.
The 372 tph of "float" from the jig goes to two 6 by 16 foot vibrating
double deck screens having 3/4-inch and 1/4-inch openings in the top and bottom
decks, respectively. Approximately 90 tph of 6 by 3/4-inch coal passes over
the top deck and goes to a crusher where it is reduced to 2 inch by 0 before
dropping onto the clean coal belt. Passing over the lower deck is 140 tph of
3/4 by 1/4-inch material which goes directly to the clean coal belt. The
1/4-inch by 0 material passing through both decks reports to a sump from which
it is pumped to four 20-inch diameter Nihard classifying cyclones at the rate
of 142 tph. The 112 tph of 1/4-inch by 48 mesh underflow from these cyclones
goes to two 6 by 16 foot desliming screens. All measurable material passes
over these screens and is fed to two centrifugal dryers which recover essen-
tially all of the feed. From the dryers, the 1/4-inch by 48 mesh material
goes to the clean coal belt.
The 30 tph of 48 mesh by 0 overflow from the 20-inch classifying
cyclones reports to a sump from which it is pumped to five 14-inch diameter
rubber-lined hydrocyclones. Of this total cyclone feed, 12 tph of 48 by 120
mesh material reports as underflow and goes to a 3 by 12 foot single deck
desliming screen. Essentially all of this material passes over this screen
13
-------
CLASS I Ft ING
CTCLtMS
HTDKOCYCLOWES
{I I \ /' ' ' \
OtSLlMIHG SCR£tHS 5 I \^ \f \ « « 120" I
..... , I ; """
'• I I OtSLIBIIIC SCKtB
6 X J/4 in M I
bo
ZinX 0
90 TPli
D=
FIGURE 1-2-2.1. COST COMPONENT EXAMPLE - JIG PROCESS -
SIMPLE PREPARATION PLANT FLOW SHEET
-------
TABLE 1-2-2.1.
COST COMPONENT EXAMPLE - JIG PROCESS - SIMPLE
WASHABILITY DATA OF ASSUMED PLANT FEED
Specific Gravity
of Separation
Float 1.40
1.40-1.45
1.45-1.50
1.50-1.55
1.55-1.60
SINK- 1.60
FLOAT-1.40
1.40-1.45
1.45-1.50
1.50-1.55
1.55-1.60
SINK-1.60
Cumulative Float
Weight, %
46.42
2.67
1.22
1.06
1.55
47.08
47.23
4.49
3.0
2.04
1.99
41.25
Ash, %
6 x 3/4
4.75
13.33
23.63
29.50
55.96
78.89
3/4 x 0
4.69
14.67
16.61
21.69
35.99
74.68
Sulfur, %
inch— 29.75
0.78
0.76
0.93
0.51
0.42
0.41
inch— 70.25
0.78
0.80
0.94
0.87
0.76
0.47
Btu/lb
percent
14,003
12,352
10,990
9,880
5,263
2,060
percent
13,810
11,737
10,219
9,712
7,707
2,388
Weight, %
of feed
46.42
49.09
50.31
51.37
52.92
100.0
of feed
47.23
51.72
54.72
56.76
58.75
100.0
Ash , %
4.75
5.23
5.66
6.15
7.61
41.17
4.69
5.55
6.16
6.72
7.71
35.34
Sulfur %
0.78
0.78
0.78
0.78
0.77
0.60
0.78
0.78
0.79
0.79
0.80
0.67
Btu/lb
14,003
13,913
13,842
13,760
13,512
8,120
13,810
13,630
13,443
13,309
13,119
8,693
-------
and goes to a centrifugal dryer before going to the clean coal belt. There
is 18 tph of 120 mesh by 0 overflow from the hydrocyclones which is split
between the jig feed sump and the sludge ponds. Of the 18 tph, 6 tph reports
to the sump from which it is pumped back to the jig and the balance (12 tph)
is sluiced to the sludge ponds along with approximately 350 gallons per
minute of water.
A total of 354 tph of 2-inch by 0 material having a heat content
of 13,236 Btu/lb drops onto the 36-inch wide clean coal belt and is conveyed
to a 40,000 ton open storage area awaiting unit-train load-out.
Holt discusses the capital equipment costs and the operating and
maintenance costs of this example. Tables 1-2-2.2 and 1-2-2.3 give details
of the costs as estimated in Holt*- ' . These figures are based on operating
the plant 2600 hours per year with a 10-year amortization of the capital
costs.
The cost component example given in Appendix B includes a simulation
of this plant configuration. No equipment performance data were given in
Holt for this plant so these data had to be assumed in this simulation.
Despite this, the results of the simulation agree well with the design data
given in Holt . As may be seen from pages 6 and 7 of Appendix B (pp. 229-230),
the simulation predicts a clean output flow of 364 tph (flowstream 26), a
refuse flow of 223 tph (flowstreams 30 and 31) with 13 tph reporting to
sludge ponds (flowstream 27). The corresponding figures from Holt are
354 tph, 234 tph, and 12 tph as seen in Figure 1-2-2.1. While the flow
rates of some flowstreams internal to the plant agree less well with Holt ,
the overall agreement of the simulation with the design is good.
16
-------
TABLE 1-2-2.2. COST COMPONENT EXAMPLE - JIG PROCESS -
SIMPLE PREPARATION PLANT CAPITAL
REQUIREMENTS(5)
RAW COAL STORAGE AND HANDLING:
Raw Coal Storage Area
20,000 Ton Capacity with Stacking Tube,
Reclaiming Feeders, and Tunnel $300,000
Raw Coal Belt to Plant
42-inch Wide - 200 Feet at $520/foot 104,000
Tramp Iron Magnet
Explosion Proof - Self Cleaning Type 20,000
Total Raw Coal Storage & Handling Cost $424,000
PREPARATION PLANT:
Equipment Cost
6 x 16 foot Single Deck Vibrating
Scalping Screen - 1 at $17,500 $ 17,500
Eight Cell Baum Type Jig - 1 at $176,000 176,000
6 x 16 foot Double Deck Vibrating
Dewatering Screens - 2 at $23,000 each 46,000
5 x 10 foot Double Deck Vibrating Refuse
Dewatering Screen - 1 at $18,000 18,000
Crusher - 1 at $12,100 12,100
Classifying Cyclones - 20 inch diameter -
Nihard - 4 at $2,400 each 9,600
Hydrocylones - 12-inch diameter - Rubber
Lined - 5 at $1,300 each 6,500
3 x 10 foot Single Deck Desliming Screen -
1 at $12,000 12,000
Centrifugal Dryer - 1 at $23,200 23,200
Centrifugal Dryers - 2 at $28,200 each 56,400
6 x 16 foot Single Deck Desliming Screens -
2 at $16,000 each 32,000
Sumps - 3 at $10,000 each 30,000
Pumps 75,000
Total Preparation Plant Equipment $514,300
Total Cost of Preparation Plant - Including Site
Preparation, Construction of Building, Electrical
Service, Piping, etc. $514,300 x 3.0 $1,542,900
(Continued)
17
-------
TABLE 1-2-2.2. (Continued)
OTHER FACILITIES AND EQUIPMENT:
Clean Coal Belt - 36 inches Wide
300 feet at $480 per foot $144,000
Clean Coal Storage Area - 40,000 ton
Capacity with Stacking Tube,
Reclaiming Feeders, etc. 350,000
Refuse Belt - 36 inches Wide
250 feet at $480 per foot 120,000
Refuse Bin 50,000
Raw Coal and Refuse Handling Equipment -
2 Dozers at $150,000 each 300,000
Unit-Train Loading Facility 500,000
Total Other Facilities & Equipment $1,464,000
SUMMARY OF CAPITAL COST:
Raw Coal Storage and Handling $ 424,000
Preparation Plant 1,542,900
Other Facilities and Equipment 1,464,000
Contingency (Interest during
Construction, etc.) 515,000
Total Capital Requirement $3,945,900
Based upon the 600 ton per hour input to this plant, the
Capital Requirement translates to $6,600 per ton/hour of input
18
-------
TABLE 1-2-2.3. COST COMPONENT EXAMPLE - JIG
PROCESS - SIMPLE OPERATING AND
MAINTENANCE
Cost Category
Cost per Ton Cost per Ton
(Raw Coal) (Clean Coal)
Labor
Supervisory (Non-Union) $0.044 $0.075
Operating and Maintenance (Union) 0.303 0.514
Overhead
Fringe Benefits - 25% Non-Union 0.011 0.019
- 21% Union 0.064 0.108
Other - Includes Welfare Fund,
Payroll Taxes, Property Taxes,
Insurance, etc. 0.059 0.100
Supplies
Operating 0.155 0.262
Maintenance 0.148 0.251
Major Maintenance - Scheduled Repairs
and Plant Improvements 0.134 0.228
Electricity 0.073 0.123
Subcontract Services to Dip Sludge Ponds,
Haul Refuse and Miscellaneous Expenses 0.599 1.016
O&M Cost - Not Including Capital Amortization $1.59 $2.70
Capital Amortization - 10 yrs.-30% Utilization 0.38 0.65
Total Operating & Maintenance Cost $1.97 $3.35
Cost Per Million Btu (12,111 Btu/lb) $0.138
19
-------
3.0 REPRESENTATION OF FLOWS
The fundamental notion within program CPSM4 is that of a flow of
coal. It is these flows which the unit operations manipulate. Each unit
operation accepts certain flows as input and produces certain flows as
output. All of the mathematical operations performed by the routines
simulating the various units manipulate flow representations. Furthermore,
from the standpoint of the user of the program, the performance of any given
unit is measured in terms of the changes induced in the flows being
manipulated. This fact corresponds to the real world situation in that an
engineer can evaluate the performance of a given unit or a circuit or an
entire plant only by studying the characteristics of the output flows of
coal as measured in terms of the characteristics of the input flows.
Describing the mathematical algorithms used to simulate a particu-
lar type of unit operation in a coal preparation plant involves describing
how the relevant portions of the program manipulate flow representations.
This chapter, then, describes how flows of coal are represented in program CPSM4,
Associated with each flow are two types of information:
(1) F - the amount of material of characteristic t
t,s,g
in the s-th size fraction and g-th specific gravity
fraction.
(2) W - the amount of water in the flow.
In addition, there is a third type of information which, while not associated
with the flows internally in the program, is helpful in determining the effect
of a given unit operation on a flow. This is the characteristic value, C ,
t »s, g
which is the percentage by weight of material of characteristic t that is in
size fraction s and specific gravity fraction g, except that for the Btu
characteristic, C is the Btu per pound.
f- o rr r
L J ^ ? &
These are measures of the amount of material within the flow. They
may be thought of as weight measures or as rate of flow measures. For the
characteristics commonly included in CPSM4, the flow description F aives
t'Sjg '
for size fraction s and specific gravity fraction g, the following information:
20
-------
(1) Total weight of dry material in the flow per time period.
(2) Weight of ash in the flow per time period.
(3) Weight of total sulfur in the flow per time period.
(4) Weight of pyritic sulfur in the flow per time period.
(5) Total Btu in the flow per time period.
For the ash and sulfur characteristics the type of weight unit used is unimpor-
tant insofar as the mathematics of the program is co.ncerned, so long as all
the flows are thought of as being measured in the same units. The total weight
of material in the flow is assumed in the program to be in tons, or tons per
hour; the amount of water in the flow is assumed to be in the same units but
for output purposes is converted to gallons per minute.
21
-------
3.1 The Uniformity Assumption
An important assumption made about the interpretation of the flow
characteristic values is that of uniformity. This part discusses that
assumption. It is an explicit assumption within the program that all char-
acteristics which pertain to a given size and/or specific gravity fraction
are uniformly distributed over that fraction. In other words, it is assumed
that all of the material in that fraction has the same value for the char-
acteristic being measured.
To make the impact of this assumption a bit clearer, consider
Figure Ir-3-1,1, which shows the direct percent ash plotted versus specific
gravity for the composite feed shown in Table 1-2-3.1. The area bounded by
the rectangles shows the relationship under the uniform distribution hypoth-
esis; while the other line was formed by connecting the midpoints of the
specific gravity fractions.
Assume now that an estimate were desired for the direct percent
ash for the material at some specific gravity - say 1.60. Under the uniform
distribution hypothesis, the answer would be 33 percent while under the hy-
pothesis connecting the midpoints it would be 30 percent. In the particular
application chosen, the 30 percent answer seems better. Equivalent results
could be obtained when looking at averages over specific gravity intervals.
Thus, the average direct percent ash for the interval 1.60 to 1.70 would
simply be 33 percent while under the other it would be 32 percent.
In each case, the second estimate, which does not assume a uniform
distribution, seemed better. The reason is obvious. As specific gravity
increases, the direct percent of ash also increases. The second assumption
captures this additional relationship, while the uniformity assumption does
t
not. Why then does the program assume uniformity? There are two reasons.
First, the uniformity assumption is computationally much simpler to implement,
and second, it is not obvious what different assumption would give better re-
sults in general. It is not at all certain that all variables would vary as
neatly as does direct percent ash. From the standpoint of maximal generality,
the uniformity assumption is both easy to implement and reasonable. From
22
-------
to
tfl
4-1
a
OJ
a
o
0)
S-i
100
90 -
80 -
70 -
60 -
50 -
40 -
30-
20-
10 _
r
0.0
I i r r i ^ ' r i
1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20
Specific gravity
FIGURE 1-3-1.1. DIRECT PERCENT ASH
23
-------
the standpoint of this discussion, it is important only that the reader
understand that this assumption is being made and that he be a little wary
as a result. The only point where difficulties might arise is in the screening
algorithm. (See the discussion of the uniformity assumption in screening
given in Part 1-04-03.)
The above comments are not intended to imply that the application
of the uniformity assumption can lead to problems in maintaining the material
balance. This is not true. The material balance will always be maintained
by CPSM4. This topic will be discussed in detail in Part 3 of Chapter 4 of
this section, which discusses the screening unit operation.
24
-------
3.2 Classifying Unit Operations
An important way in which the algorithms for the unit operations of
Figure I-1-0.1 can be distinguished is by whether or not the result produced
by the algorithm has any impact on the values for the C . A given unit
t, s, g
will be said to have characteristic invariance, if, and only if, all output
flows for the unit have the same set of C as the input flows. Within
f- Q O- r
L J => 5 6
program CPSM4 the following unit operations exhibit characteristic invariance:
• Single-stage washing
• Two-stage washing
• Froth flotation
• Screening
• Splitting.
The following do not exhibit characteristic invariance:
• Rotary breaking
• Crushing.
Blending is a special case in that it has characteristic invariance if and
only if all input flows have identical values for the C . The above
t ,s ,g
points will be developed more fully in the parts dealing with the particular
unit operations (see Chapter 1-04).
Closely related to the notion of characteristic invariance for
classifying algorithms for unit operations is the notion of characteristic
independence. The algorithm for a given unit operation will be said to
exhibit characteristic independence if and only if the algorithm does not
take the values of the C for the input flows into account in determining
f" O CT
"- > b 5 &
the values of the F^ for the output flows. Within CPSM4 only the algorithm
t, s, g
for the froth flotation cell does not have characteristic independence. On
the other hand, it does have characteristic invariance.
Now that the basic flow representation has been described, the unit
operations can be discussed. The discussion will assume the notation and basic
concepts developed in this chapter.
25
-------
3.3- Retreatment.Flows
Much of the water in a coal cleaning plant is recycled within the
plant. In order to'be able to simulate this recycling, it is necessary to be
able to model retreatment streams. Such flowstreams have the property that
-*
they are input streams to units which occur earlier in the configuration than
the unit at which they are computed. Thus, on the first cycle through the
configuration, the retreatment flowstreams have unknown properties. For
example, in the User Handbook example of Appendix A, flowstream 25 is an
output flowstream from unit 15 and an input flowstream to unit 2. When
unit 2 in the configuration is simulated initially, the properties of the
input flowstream 25 are unknown; they are not computed until unit 15 has
been simulated. CPSM4 has been modified so that in the event of retreatment
streams being present, the entire configuration will be processed as many
times as is necessary to achieve convergence of the composite characteristics
of the retreatment flowstreams. It is assumed that only blenders will have
input streams that are retreatment streams. This means that the check to
determine whether the current unit is a retreatment unit need be done only
for blenders. On the'first pass through the configuration, the retreatment
streams are assumed to be empty (although if they contain water, this will
automatically be added by the blender if the percent moisture decision
variable is present)'. On subsequent passes through the configuration, the
characteristics used for the retreatment streams are those calculated on
the previous iteration.
For a retreatment unit,the number of input streams to the unit is
fewer on the first pass through the configuration than on subsequent passes
since the retreatment streams are ignored at first. So the retreatment unit
must be able to handle a variable'number of.input streams, effectively
restricting, such units to being blenders.. Blenders are able to blend from one
to six input streams.
To reduce the number of iterations required for convergence of the
retreatment flowstream characteristics, the convergence acceleration procedure
used in the original version of CPSM4 was used in the present program. This
26
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is the Aitken-Steffenson convergence acceleration procedure in which, after
three evaluations XQ, x^, x^ of the flow rate of a retreatment stream, a new
flow rate x is computed from
i = _ (xi - xo)2
2 (x2 - 2xx + XQ) '
x is then used as the starting point x~ from which to calculate x and from
1 11
that x and hence a new x . Thus, on all odd iterations through the config-
uration except the first, the flow rate is adjusted by the formula given above
so as to accelerate convergence. Since CPSM4 stores all the detailed flow-
stream data in additive form, the adjustment of the coal flow rate is made to
all elements in the detailed flow description array. This is done by computing
the scale factor x_ /x? and scaling all the flow description elements by this
amount. The flow rate of the water in the stream is also adjusted by this
convergence acceleration procedure.
27
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4.0 THE UNIT OPERATIONS
Within program CPSM4 flows are manipulated by units within the user
specified plant configuration whose mathematical treatment of the flow repre-
sentations is intended to model the effect on actual flows of coal of actual
units of equipment in a coal preparation plant. Each unit that the user
specifies is assigned an equipment type. Figure 1-1-0.1 showed the types of
equipment which have been modeled to date using program CPSM4. Within a given
plant configuration, there may be several non-identical units of the same
equipment type. Different units of the same equipment type are distinguished
via the values of particular decision variables. As an example, a given con-
figuration might have two wet upper screens, one with a mesh size of 1-1/2
inches and one with a mesh size of 8 mesh. Both would be simulated with the
same equipment type. One would have a decision variable setting of 1.5 inches;
while the other would have a setting of 8 mesh. This concept will be developed
fully in the following discussion.
The notion of a unit operation is one level of abstraction above that
of an equipment type. Many different equipment types may be mathematically
implemented via the same unit operation. Figure 1-1-0.1 showed the nine unit
operations currently implemented in the program along with the equipment types
using them. Any two equipment types using the same unit operation have the
same general mathematical approach'—i.e., model structure. They differ in terms
of the actual values of coefficients within the equations used to actually im-
plement the mathematical structures.
This chapter describes in considerable detail the mathematical treat-
ment given to the flow representations by the nine unit operation types.
28
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4.1 Blending
The mathematics of blending is perfectly straightforward. A blender
has one output flow and up to six input flows. If F represents the flow
o,t,s,g p
description of the output flow and F (i = 1,...,6) represent the flow
J- • > t, s , g
descriptions of the input flows, then
F = I FT . (1)
o,t,s,gili,t,s,g
If W represents the water content of the output flow and W (i = 1,...,6)
represent the water contents of the input flows, then
W = I WT . (2)
o . I.
i i
These two equations complete the basic description of the mathematics of
blending. However, there is an additional feature which may be used to increase
the amount of water in the output flow. The user may supply a desired percent
moisture level for the output flow. Such user-specified variables are referred
to as decision variables . If the desired percent moisture level of the output
flow is Dl and if Dl is greater than the percent moisture of the output flow as
determined from equation 2, then W is modified to increase the percent moisture
level to Dl . Note as stated on page 1-03-00-02 that for t equals 1, F contains
the total weight of material.
W
°
W + E F n
O S,g 0,1, S,
Dl Z F
"°
Note that while a blender can add water to the plant, it can never decrease the
amount of water in the output flow so as to "lose" water from the plant. The
blender is the only unit operation capable of adding water in this manner. No
unit operations "lose" water.
29
-------
The calculation of the characteristic values of the output flow,
from CT _ is slightly more complex than the above. Now
''
_
C0 t s e = Fo>t,s,g _ (5)
o,t,s,g. .
S,g 0,1, S,g
so that
o,t,s,g ± I^r.s.g £ gjg I±,l,s,g
T «- T T
_ I ,t,s,g s,g I ,l,s,g
Z E FT ,
is,g Ii'1'8'8
In terms of the constancy of the characteristic values, note that if
K ~ CI t s e ' 1 ~ 1'"< '6
<-J-. , t- , o , S
then C = E K • E FT . / E E F,. ,
°'t'S'8 i s,g Ii'1's'S: i s,g V1'3'8
= K E E FT / E E FT. . (7)
i s.g Ii'1'S'g i a.g Ii'1'S'8
= K
Thus, if all input flows have the same characteristic values, then the output
flow will have that .same set of characteristic values. This is characteristic
invariance as'defined earlier.
As an example of the calculation of the-characteristic values of
the'output flow of a blender, assume that two coal"streams are blended;
one having 2000 T of coal containing 10% moisture', 2% sulfur and having
30
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12,000 Btu/lb, the second flowstream having 1000 T of coal containing 6%
moisture, 1.4% sulfur and having 14,000 Btu/lb. Then
F = 1800 T = weight of dry material in flowstream 1
J- » -L
F? = 940 T = weight of dry material in flowstream 2
/ , x
F = 36 T = weight of sulfur in flowstream 1
-L, o
F
9 _ = 13.16 T = weight of sulfur in flowstream 2
z, o
Q
F = 432 x 10 Btu = total Btu in flowstream 1
-L, _>
o
F9 = 263.2 x 10 Btu = total Btu in flowstream 2
/ , j
W = 200 T = weight of water in flowstream 1
W~ = 60 T = weight of water in flowstream 2
C = 2 = % sulfur in flowstream 1
J_, 3
C9 _ = 1.4 = % sulfur in flowstream 2
z, o
C, = 12,000 = Btu/lb for flowstream 1
J-> ->
and C = 14,000 = Btu/lb for flowstream 2.
2 5 ->
If flowstream number 3 represents the output of the blender, then
F_ = 2740 T = weight of dry material in flowstream 3
3 > 1
F = 49.16 T = weight of sulfur in flowstream 3
3,3
o
F., = 695.2 x 10 Btu = total Btu in flowstream 3
3 , _>
and W = 260 T = weight of water in flowstream 3.
The characteristic values of flowstream 3 are
C,, _ = % sulfur in flowstream 3
3,3
= (c F +T F )/(F +F )
^1,3^1,1 °2,3 2.rM 1,1 2,1;
= (2 x 1800 + 1.4 x 940)/(1800 + 940)
= 4916/2740
= 1.79
31
-------
and C_ _ = Btu/lb for flowstream 3
= (12,000 x 1800 + 14,000 x 940)7(1800 + 940)
= 34,760,000/2740
= 12,686.
In addition, the percent moisture of the output flowstream is computed as
W
3 rxlOQ= (27406+°260) Xl00 = 8'67%
32
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4.2 Splitting
The mathematics of splitting are as straightforward as those of
blending; however, splitting requires that the user specify a decision variable
in addition to an optional percent moisture decision variable. The following
discussion describes the mathematics of splitting.
Splitting is viewed as being a simple unit operation which takes one
input flow, whose quantities will be represented by the subscript I_ , and
produces two output flows, whose quantities will be represented by the sub-
scripts U_ (for upper) and L^ (for lower). The required decision variable, Dl,
specifies the percentage of material in the input flow that is to be sent to
the upper output flow. The output flow descriptions are given by
(1)
U,t,s,g 100 I,t,s,g
F = F - F (2)
L,t,s,g I,t,s,g u,t,s,g
Splitting is set apart from the other unit operations in that the two flows
out of the splitter are assumed to have characteristic values identical to
those of the input flow and the same distribution of material. The charac-
teristic values of the output flows are
F
C = u»t.s,g = Dl , Dl F
u,t,s,g E F 100 I,t,s,g' s,s 100 I,l,s,g
u,±,s ,g
0 > 6
s,g
T -
FT = I,t,S,g U,t,S,g
_ *-> > t- ? ° 9 & _ y
L,t,s,g E F s,g
FT E F
= I,t,s,g • s,g
E F n E
s,g I,l,s,g s,g
33
-------
F <- E F 1
u,t,s,g s,g u,l,s,g
E F E/F_ . - F \
s,g u,l,s,g s,g^I,l,s,g u,l,s,gj
C *EF — C °EF
= I,t,s,g s,g I,l,s,g u,t,s,g s,g u,l,s,g (4)
E /F
s,g
\
u,l,s,gj
C E F — C E F
= I,t.S,g S,g 1,1,3, g I,t,S,g S,g U,l,S,g
E /F - F \
s,g ^ I,l,s,g u,l,s,gj
I,t,s,g
Thus, the only difference between the three flows of a splitter is the quantity
of material in each flow.
In the absence of a second decision variable, the water content of
\
the input flow is divided between the upper and lower output flows in the same
ratio as the f lowrates . Thus, in this case the percent moisture content of
each output flow is the same and is the same as that of the input flow.
However, it is possible to specify the percent moisture content of the upper
output flow by specifying a second decision variable, D2. This allows a
splitter to be used to remove water from a flowstream so that, for example,
a dryer or centrifuge may be simulated. If the decision variable D2 is
specified, then
WU = D2sSS FU 1 s R ' (1°° - D2)
u °56 Uj-Ljt>»6
and
34
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4.3 Screening
The implementations of the blending and splitting operations within
the coal preparation process were simple in that they were purely mathematical
independent of any real empirical data. This simplicity is not possible for
the remaining unit operations, as all require empirical data. This empirical
data is entered by the user in the form of distributions as well as via
decision variables. This discussion introduces this concept and describes the
mathematics of screening.
The approach taken to screening assumes that there will be no over-
sized particles in the underflow, but that there will be undersized particles
in the overflow. This assumption is based on the fact that a particle
smaller than the screen mesh size does not necessarily pass through the screen.
The opposite, however, that a particle larger than the screen mesh size will
not pass through the screen is assumed to be true. Associated with any given
particle, then, is a probability that that particle will not pass through the
screen. This probability, pr, is a function of the particle size and the
screen size. Its form is shown in (1) below.
1.0 if ps >_ ss
f \ (1)
pnss.ps; -A(ss)-(l-ps/ss) if ps < ss
where
ss is the screen mesh size
ps is the particle size
A is a screen type specific distribution over the mesh size.
Vaillant , which contains some documentation for the original
version of CPSM4, gives a justification for the use of an exponential form
for the probability of a particle passing through a screen but does not
attempt to justify the use of an exponential form for the probability of
a particle not passing through a screen. This equation (1), while reasonable,
must be said to be of unclear origin.
35
-------
The empirically derived adjustment factors, A, have been estimated
by Vaillant*'6'' for four types of screens. Each distribution is a function
of mesh size. Figure 1-4-3.1 shows these distributions in graphical form.
Table 1-4-3.1 shows the actual values as they are to be entered into program
CPSM4.
To simulate a screen, the user must enter two types of information. .
First, he must enter the distribution from which the program is to obtain
the adjustment factor. This distribution might be used in more than one
actual unit in the plant configuration. It would be used for all screens of
the same general type. Second, the user must enter a decision variable, Dl,
representing the mesh size for each particular screen in his plant configuration.
TABLE 1-4-3.1. ADJUSTMENT FACTORS FOR SCREENING
Mesh size,
inches
18.0
6.0
1.5
.375
.25
.093
.0232
.0164
.0116
Dry upper
screen
60.0
20.0
8.0
8.0
5.0
3.0
0.7
0.6
0.5
Dry lower
screen
60.0
20.0
8.0
6.0
4.0
2.0
0.7
0.6
0.6
Wet upper
screen
60.0
20.0
9.0
8.6
5.5
3.5
0.8
0.7
0.55
Wet lower
screen
60.0
20.0
9.0
6.6
4.5
2.3
0.8
0.7
0.55
36
-------
10.0
9.0-
7.0-
6.0-
5.0
4.CH
3.0-
0.2
0.4
Dry Upper Screen
_ _ _ Dry Lower Screen
Wet Upper Screen
Wet Lower Screen
0.6 0.8 1.0 1.2
Screen size, inches
FIGURE 1-4-3.1. ADJUSTMENT FACTORS FOR SCREENING
1.4
1.6
37
-------
The details of the entry of this information are discussed at length in later
parts of this section. It should also be noted that screens can be simulated
using explicit classification curves as well. This topic will be discussed
in the next chapter.
There is one problem associated with the above formulation. This
is that the actual sizes of the particles are unknown. Rather, as discussed
earlier, the flow is classified and described generally in terms of size
fractions. The size distribution of the coal is defined, not the individual
particle sizes. The problem then becomes not to estimate the probability
that a given particle will pass through a screen, but rather to estimate the
proportion of particles that will not pass through the screen within each size
fraction based on the size range of that fraction.
Let S . and S be the minimum and maximum size values for the
mm max
material within a given size fraction s. By assumption, the pair {S S )
min, max
forms a closed open interval. Thus, any particle within s has a size greater
than or equal to S . and less than S . Now there are three possible cases.
mm max
(1) S > S . > ss
max mm
(2) S >. ss >. S .
max mm
(3) ss > S > S .
max mm
Case 1 is straightforward. All material is larger than the screen size, and
the ratio of material that will not pass through is 1.0. In Case 3 all the
particles are smaller than the screen size. In this case, the algorithm
assumes that all particles have size (S + S . )/2 (see the discussion of
—— max mm
uniformity assumption earlier).
Thus, the proportion of particles that will not pass through the
screen equals the probability that a particle of size (S + S . )/2 will not
max min
pass through. Case 2 is a combination of cases 1 and 3. Using the uniform
distribution assumption, the program computes the fraction of particles greater
than the screen size and treats these as Case 1. The remainder of the
38
-------
particles are smaller than the screen size and are treated as Case 3. The
resultant probability is the weighted average of the two calculations.
The basic approach, then, is to compute a set of values d (s being
5
a size fraction), which defines the proportion of the material or flow in
each size fraction that will not pass through the screen. It is important
to note that the calculation of d is strictly a function of the screen size
S
and type and the definition of the size fractions. It is independent of any
flow specific information.
Once d has been calculated, the generation of the new flow repre-
s
sentations is as follows. Let the subscript !_ represent the input flow
values and the subscripts IJ and L_ represent the upper (overflow) output flow
and lower (underflow) output flow, respectively. The remaining notation is
as before.
F = d F
U,t,s,g s I,t,s,-g
L,t,s,g I,t,s,g s
C = C
U,t,s,g I,t,s,g
C = C
L,t,s,g I,t,s,g (2)
IT - I S,g U,l,S,g
WU ~ Z FT .
s,g I,l,s,g
WL ' WI - WU
However, the user may enter a second decision variable, D2, representing the
desired percent moisture of the upper (overflow) output flow. In that case,
D2 £ FTT .
w = s,g U,l,s,g
WU (100 - D2)
39
-------
Notice that the screening process is nonselective both in terms of
specific gravity and the characteristic values. In particular, the character-
istic values of the two output flows are identical to each other and are
identical to the characteristic values of the input flow.
There is one difficulty in the preceding discussion which the user
should be aware of. The assumption of uniform distribution and the assump-
tion that no particle larger than the screen size will pass through it are
incompatible. Assume, for example, that the program is simulating the passage
of material classified in the size fraction 1/8-inch by 10 mesh (0.065
inch) passing through an 8 mesh (0.093 inch) screen. Now by the assumption
that no material larger than the screen size will pass through, most of the
material will not be in the underflow stream and that material which is in
the underflow screen will all be less than 8 mesh - i.e., it will be in the
8 to 10 mesh size fraction. However, the program assumes the same size
classification for all flows and assumes that these are all uniformly classi-
fied in those size fractions; therefore, all subsequent processing of the
underflow from the 8 mesh screen will assume that the material in the size
category is 1/8 inch by 10 mesh and not 8 mesh by 10 mesh. In cases where
little detailed sizing data are available, this incompatibility could cause
strong biases in the results.
Upon first seeing the above and possibly, upon considering the
uniformity assumption in general, the reader might be led to believe that in
cases where a screen mesh size does not fall directly on a size fraction
boundary the program might not maintain the material balance of the flows.
Thus, he might interpret the phrase "strong biases in the results" as used
in the preceding paragraph as referring to biases in the material balance.
As was stated earlier in this section, this is not the case. The program
always maintains the material balance, as it must if the results are to be
meaningful. The remainder of this part will discuss this issue with regard
to the implementation of the double deck screen in the user handbook example.
The detailed mathematics of this issue are quite complex and will not be
dealt with in this section. Part 2 of Chapter 4 in Volume II discusses the
mathematical problems.
40
-------
The uniformity assumption comes into play not just when the
characteristics of size fractions are needed but also to determine what parti-
cular mathematical equation should apply to what size fraction. In the case
of the screen, the calculation of the value of d depends upon the size frac-
tion bounds. This was specified earlier. The biases referred to earlier
relate to the calculation of these values. To bring this point out clearly, a
particular example will be presented.
Examining the list of units on page 1 of the user handbook example,
notice that no double deck screen appears. This is because the list of equip-
ment types that the program could simulate did not include such a screen.
Instead, the double deck screen is simulated via a combination of three units -
a wet upper screen with a size of 1-1/2 inches, a wet lower screen with a mesh
1/2 inch, and a blender. The underflow of the double deck screen is the under-
flow of the lower screen and the overflow is the blend of the overflow from
the upper screen and the overflow of the lower screen. Now the coal passing
through this screen includes a fraction which is 2 inches by 1/2 inch. Since
the screen size 1-1/2 inch falls within this range, some bias in the results
might be present. The following will show this.
Page 12 of the user handbook example (p. 165) shows the summary of
performance characteristics for the upper screen. In particular, it shows a value
of 63.3 for the percent weight of the feed to the underflow. Based on the
presentation earlier, (4) shows the formula from which this value is derived.
(1-d )xlOO=(l-exp(-Ax(l-X/ss))x(l-f)+f)xlOO (4)
s
In this equation, A has the value 9.0, as can be seen from Table 1-4-3.1.
X is the material size. Using the uniformity assumption, X equals the midpoint
of the size interval below the mesh size 1.0. The screen mesh size is SS and
is equal to 1.50. f is that proportion of the material in the interval greater
than the screen size. Its calculation is shown in (5).
(2.0-1.5)/(2.0-0.5)=.3333 (5)
41
-------
Inserting these values in (4) and simplifying gives (6).
(l-exp(-9x(l-1.0/1.5))x(l-.3333)+0.3333)xlOO.
=(l-exp(-3)xO.6667+0.3333)xlOO.O=(l-0.3665)xlOO.O (6)
=0.6335x100.0=63.35
The value thus derived agrees with the value in the results of the program.
Now it is important to note that all of the material in the underflow is
assumed by this algorithm to be 1-1/2 by 1/2 inches in size, however, it is
still classified in the program as being 2 inches by 1/2 inch. Any values of
average size of material for this fraction will be computed as
(2.0+0.5)72=1.25 (7)
and not as (8).
(1.5+0.5)72=1.00 (8)
Thus, potential values of d or their equivalent for other unit operations
s
for this fraction will be biased.
Fortunately, in the example no such bias is actually generated,
since the lower mesh is 1/2 inch. However, in general this is a potential
problem of which the reader should be aware.
42
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4.4 Washing
Of the unit operations to be discussed, the most work has been
done for washing. Basically, the approach is similar to that used in
screening, in that a'distribution curve is computed which defines the ratio
of material in the input which will go to one output flow. The approach
differs from that in screening in the manner in which the distribution curve
is derived and in the fact that the washing distribution curve is both size
fraction and specific-gravity-fraction dependent.
Considering first the straightforward parts of the approach, a
washer is assumed to be a unit which takes one input flow, denoted by the
subscript 1^, and two output flows - a clean output flow, denoted by the sub-
script C^, and a refuse output flow, denoted by the subscript R.. It is possi-
ble to define a set of values, d , called the distributions curves, for the
Q CT
fa 5 6
unit which specify the proportion of each specific gravity and size fraction
category in the input flow which will go to the clean coal output flow. The
derivation of d is discussed later in this part.
s,g
Given the values for d , the calculations of the values for the
s,g
output flows are very similar to those given for the screening unit operation.
In essence, they are as shown in equations (1) and (la).
F = d FT
C,t,s,g s,g I,t,s,g
R,t,s,g ~ ~ s,g) I,t,s,g
C = C
C,t,s,g I,t,s,g
CR,t,s,g ~ CI,t,s,g
_ I s,g C,l,s,g
C £ FT .
s,g I,l,s,g
TJ = TJ _ TJ
R I C
43
-------
If the user supplies a decision variable, D2, representing the percent moisture
of the clean output flow then
D2 I F
TJ = s,g C,l,s,g (la) '
C (100 - D2)
WR * WI - WC
Notice again that the characteristic values of the two output flows are identical
to each other and to those of the input flow. Thus, washers are assumed to have
characteristic invariance.
Turning now to the calculation of the d values, observe that
s,g
coal washing equipment uses the float-and-sink principle based on the spe-
cific gravity differences between coal and its associated impurities which
typically have a higher specific gravity. This can be seen very clearly in
Figure 1-3-1.1 which shows the direct percent ash plotted against specific
gravity for the feed to the plant in the example. This figure shows that as
the specific gravity increases so does the direct percent ash.
Given the float-sink operation of the washing equipment, as the
specific gravity of the material increases the ratio of that material which
will go to the clean coal output flow, the float flow, decreases. Figure I-
4-4.1 shows a typical distribution curve holding the size variation
constant. The crucial value on this carve, insofar as this discussion
is concerned, is that of specific gravity corresponding to the y-axis
value of 0.50. This value is referred to as the specific gravity of
separation. It is at this specific gravity that the material in the input
flow is evenly divided between clean coal and refuse. Note that the unique-
ness of this value derives from the fact that the curve is monotone decreasing.
No two different specific gravities can have the same ratio to clean coal.
The washing unit operation, then, requires a distribution curve to
serve as the basis for its implementation. These distribution curves must
be supplied by the user much as a curve describing the adjustment factor was
required for the screening unit operation. Under one mode, the user simply
defines the distribution curves which he has available for the particular
piece of washing equipment and the program applies them.
44
-------
1.00
CO
O
a
c
0)
rH
O
O
4-J
O
•H
JJ
CO
,50
1.2
1.6
Specific gravity
2.0
FIGURE 1-4-4.1. TYPICAL DISTRIBUTION CURVE
45
-------
In many cases, however, the user of the program may not have
available to him detailed actual distribution curves for the washing
equipment to be simulated. In these cases some general description of the
operation of particular types of washing equipment is needed. Such general
descriptions have been prepared by the Bureau of Mines and are discussed in
Gottfried and Gottfried and Jacobsen . The following subparts discuss
the original formulation of generalized distribution curves and the modifica-
tion of them to c-generalized distribution curves as used in the current
version of CPSM4.
4.4.1 Generalized Distribution Curves
As was shown earlier, if the distribution curves are known for a
given unit, then the representations of the two output flows for a given
input flow are easy to calculate. The problem is that the curves are high-
ly variable relative both to the size of the material and to the specific
gravity of separation desired. The approach taken was to represent a set
of distribution curves derived empirically in a manner independent of the
specific gravity of separation. The ratio to clean coal is expressed not
in terms of specific gravity, but rather in terms of the ratio of specific
gravity by the specific gravity of separation. The basic assumption made
in the formulation of the generalized distribution curves is that all of
the variation in the distribution curves observed for a given type of wash-
ing unit can be explained via a variation in the specific gravity of sep-
aration for those curves.
Table 1-4-4.1 shows a set of distribution curves taken from
(9)
Deurbrouck and Hudy . It was based on the data from which Gottfried and
/Q\
Jacobsen computed the values for the generalized distribution curves.
This table also includes the values of reduced specific gravity cal-
culated for each curve. These values of reduced specific gravity were
computed by dividing the column marked "specific gravity" by the specific
gravity of separation for the size fraction. Given these values of reduced
specific gravity and of percent to clean, Gottfried and Jacobsen(8) plotted
them in scatter diagram form. The actual generalized curves were then
estimated by hand drawing curves through the scatter diagrams.
46
-------
TABLE 1-4-4.1. DISTRIBUTION CURVES AND GENERALIZED DISTRIBUTION CURVES FOR 1/4 INCH BY
8 MESH SIZE FRACTION FOR DENSE-MEDIUM CYCLONE WASHERS
Specific
gravity
Float-1.28
1.28-1.30
Float-1.30
1.30-1.35
1.35-1.40
1.40-1.45
1.45-1.50
1 .50-1.60
J .60-1. 70
1.70-1.80
Specific
1.
1.
1.
] .
1.
1.
1.
1.
1.
1.
.27
29
28
.325
375
425
.itlj
.55
.65
75
Plant
Reduced
speci fie
—
.826
.855
.867
.919
.952
1.000
1.065
1.129
A
Percent
to
--
99.9
99.8
99.8
98.2
95.5
49.9
5.7
0.0
Plant
Reduced
specific
.847
.860
—
.883
.917
.950
.983
1.033
1.100
1.167
B
Percent
to
100.0
99.9
—
100.0
99.9
98.5
74.4
19.3
0.0
0.0
Plai
Reduced
specific
—
.837
.866
.899
.931
.964
1.013
i.o: J
1.144
it C
Percent
to
—
99.9
99.8
99.4
98.9
93.8
33.2
1.6
0.0
Plant
Reduced
specific
gravity
.888
.902
—
.927
.962
.997
1.031
1.084
1.154
1.224
D
Percent
to
clean
99.4
99.4
—
98.5
92.1
57.1
16.6
3.2
2.1
0.0
Plant
Reduced
specific
grav y
.864
.876
—
.901
.935
.969
1.003
1.054
1.122
1.190
E
Percent
to
c ean
100.0
99.7
—
99.7
99.5
95.5
49.7
8.2
0.4
0.0
Plant
Reduced
specific
—
.908
.940
.975
1.011
1.046
1.099
1.370
1.241
F
Percent
to
c ean
—
99.1
99.0
90.6
37.3
7.7
4.9
0.0
0.0
Plant
Reduced
specific
—
.877
.908
.942
.976
1.010
1.062
1.130
1. 119
G
Percent
to
c
—
95.8
95.5
90.7
75.0
37.6
13.5
5.6
3.7
Specific gravity of 1.55 1.50 1.53 1.43 1.47 1.41 1.46
separation for fraction
Specific gravity of 1.55 1.51 1.53 1.42 1.48 1.42 1.45
separation of composite
-------
There is one problem associated with the use of the generalized
curves which relates to the fact that separate generalized distribution
curves were estimated for the various size fractions available. It was this
problem which eventually led to the formulation used in the present version
of CPSM4 of c-generalized distribution curves. This current formulation
will be discussed in the next subpart.
In essence, the decision variable to be used with the washers is
the specific gravity of separation desired for the composite separation to
clean coal. But the specific gravity of separation for the composite does
not typically equal the specific gravity of separation for some size frac-
tion within that composite. This fact is illustrated on the bottom two rows
of Table 1-4-4.1 which show the specific gravity of separation for the size
fraction and for the composite that contained that fraction. Some tech-
nique then is needed to estimate the desired specific gravity of separation
for individual size fraction specific distribution curves based on the
desired composite specific gravity of separation specified as the decision
variable for the unit.
(8)
The approach taken by Gottfried and Jacobsen was to estimate
for any given size fraction s, the ratio •
rs = PS/PC (2)
where p is the specific gravity of separation for the s size fraction and
S
p is the composite specific gravity of separation. These estimates were
c
made from the same data as was used to estimate the generalized curves.
A desired specific gravity of separation P for a size fraction
Q j S
s can then be computed from the desired composite specific gravity of separa-
tion P, by the equation shown in (3).
d,c
P^ = p , • r (3)
d,s d,c s
Given the above, the distribution curve value dg for a given
size fraction s and a given specific gravity fraction g with specific gravity
p can be computed from the generalized curve Gg as shown in (4).
ds,g = Vg/^d.c-'s" (4)
48
-------
Each type of washing unit was represented by two sets of values — the
values defining the generalized curves for each size fraction and the ratios
for computing the size fraction specific gravities of separation.
4.4.2 C-Generalized Distribution Curves
From the standpoint of the current version of program CPSM4, the
calculation of d as shown in equation (4) is objectionable for three
3 Ȥ
reasons. First, it is computationally inefficient since it requires
a multiplication by the value r before a value can be obtained from the
s
function G . Ideally, the argument to G should simply be p /p. . Second,
s s g d, c
it is inefficient from the standpoint of storage since it requires the
additional storage of the values for r . Third, the use of the r values
S S
requires that they too be estimated from the data in addition to the gen-
eralized curves themselves.
The approach taken in the current version, then, was to compute
the reduced specific gravity based not on the specific gravity of separation
for the individual size fractions but rather on the composite specific
gravity. The dependence of the function argument upon the size fraction
was transferred to the fraction itself by scaling, thus producing identical
results while simplifying the form of the argument. The curves so formed
will be referred to as c-generalized (^c_ for composite) curves. Using a
c-generalized curve, the calculation of the values for d is simply as
s > 8
shown in (5) .
d = G° (p /p , ) (5)
s,g s g d,c
c
Here G represents the c-generalized curve for the size fraction s.
s
This formulation is more efficient computationally, requires less storage,
and is easier to estimate.
Actually, the c-generalized approach makes a somewhat different
empirical assumption than does the generalized one. The basic assumption
made in the formulation of c-generalized distribution curves is that all of the
variation in the distribution curves for a given type of washing unit can be
49
-------
explained via a variation in the composite specific gravity of separation for
those curves. There appears to be no intuitive or logical reason to choose
the one assumption over the other. Selection could be made based on the
statistical goodness of fit derived for a curve based on the generalized
approach versus the c-generalized approach. Unfortunately, the generalized
curves were not obtained via a statistical technique; therefore, no such
comparison could be made. Ultimately, the c-generalized approach was
taken simply because it is simpler and more efficient from a programming
standpoint.
From a logistics standpoint, the only other problem associated with
reformulating the approach to generalizing the distribution curves derived from
fQ\
the desire to maintain all other assumptions made by Gottfried and Jacobsen
in the new formulation. If this could be done, then the c-generalized
curves would produce values for d identical to those produced by the
s » 8
generalized ones. To accomplish this, the c-generalized curves were
computed directly from the values specified for the generalized curves simply
by multiplying the x-axis values of the generalized curve by the specified
value of r for that curve.
s
To show that the curves thus produced do in fact take p /p as
g d,c
an argument and do in fact produce the same results as the curves which
take P /(P, • r ) as an argument, requires the introduction of the notion
g a , c s
of interpolation. Values for functions at arbitrary points are computed from
a finite set of specified points via an interpolation calculation. The
simplest type of interpolation is linear interpolation. Equation (6) shows
the formula for linear interpolation.
Y = ((Y^-YJ ' (Xi-X)/(Xi-X1^1)) + Y± (6)
where Y is the desired functional value
X is the specified argument
i is the index of the specified x point immediately greater than
or equal to X
i-1 is the index of the specified x point immediately less than X.
Now for any given p , r , and p the generalized curve would give equation (7).
g s d , c
50
-------
Y =
• (xiV(vpd,c))/(vxi-i)) + Yi
The c-generalized curve computed from the generalized one would give the
identical equation (8) .
Y = ((Y.^-Y.) • (X.-rs - Pg/Pd>c))/(X1-rs - X.^-O) + Y. (8)
= ((Y. -Y.) • (X.-r /(X.-r -X. -r ) - p / (p • (X.-r -X. -r ))) + Y.
i-l i i s i s i-l s g d,c i s i-l s i
= ((Y. -Y.) • (X./(X.-X. ) - P /(P -r -(X.-X. ))) + Y.
i-l i 11 i-l g d,c s i i-l i
Therefore, the two formulations produce identical results under linear inter-
polation. To show the same result for other types of interpolation, such as
Lagrangian which is actually used, is straightf orward though tedious; there-
fore, it will not be done here.
The actual values to be used for the c-generalized curves for the
five types of washing equipment for which estimates were originally made by
r o\
Gottfried and Jacobsen are shown in the following five tables, 1-4-4.2
through 1-4-4.6.
51
-------
TABLE 1-4-4.2. C-GENERALIZED CURVE DATA FOR CONCENTRATING TABLE BY SIZE FRACTION
Plus 1/2
c-P.educed
specific
.8181
.8694
.9793
.8892
.9030
.9] 29
.9218
.9267
.9416
.9586
.9880
1.0186
1.0532
1.0581
1.0670
1.0769
1.08,68
1.0977
1.2844
1.4820
inch
Batio
to
clean
1.000
.993
.987
.978
.960
.940
.920
.900
.800
.690
.500
.300
.080
.060
.043
.033
.026
.023
.011
.000
1/4 inch
c-Reduced
specific
gravity
.8290
.8509
.8648
.8747
.8847
.8966
.9045
.9314
.9433
.9642
.9940
1.0288
1.0387
1.0626
1.0835
1.1093
1.1332
1.1610
1.1928
1.5467
by 8 mesh
Ratio
to
clean
1.000
.997
.993
.987
.977
.963
.948
.900
.800
.675
.500
.300
.240
.180
.099
.060
.040
.026
.018
.000
8 mesh by
c-Reduced
specific
gravity
.7646
.82/9
.8425
.8620
.8766
.8961
.9058
.9497
.9740
1.0227
1.0519
1.0665
1.0909
1.1201
1.1688
1.2272
1.6558
1.7532
1.8506
1.9480
14 mesh
Ratio
to
clean
1.000
.997
.994
.981
.960
.920
.880
.635
.500
.279
.148
.100
.068
.046
.025
.018
.000
.000
.000
.000
14 mesh by
c-Reduced
specific
gravity
. 7362
.7954
.8051
.8245
.8391
.8488
.8633
.8827
.9021
.9700
1.037.9
1.0573
1.0864
1.1252
1.1689
1.2853
1.4308
1.6189
1.7460
1.9400
28 mesh
Ratio
to
clean
1.000
.993
.991
.983
.972
.962
.939
.887
.817
.500
.246
.195
.145
.103
.073
.040
.015
.000
.000
.000
28 mesh by
c-Reduced
specific
gravity
.7515
.7813
.8018
.8306
.8635
.8861
.9252
1.0280
1.1514
1.1925
1.2336
1.2953
1.3364
1.3981
1.6448
1.8504
2.0560
2.1074
2.1588
2.2102
48 mesh
Ratio
to
clean
1.000
.994
.987
.968
.932
.900
.800
.500
.200
.135
.099
.066
.052
.040
.026
.021
.020
.020
.020
.020
48 mesh by
c-Reduced
specific
gravity
.7479
.8122
.8798
.9250
.9723
1.0017
1.0332
1.1280
1.1573
1.1731
1.2171
1.2634
1.3762
1.3987
1.4326
1.4890
1.5566
2.2560
2.3124
2.3688
100 mesh
Ratio
to
clean
1.000
.977
.941
.908
.862
.823
.758
.500
.420
.375
.300
.237
.100
.080
.060
.040
.030
.020
.020
.020
Minus 100
c-Reduced
specific
gravity
.7345
.7757
.8242
.8775
.9211
.9696
1.0132 v
1.0326
1.0908
1.2120
1.2847
1.3623
1.4544
1.5998
1.6968
1.9392
2.4240
2.4846
2.5452
2.6058
mesh
Ratio
to
clean
1.000
.998
.992
.981
.969
.947
.919
.900
.800
.500
.400
.339
.292
.243
.219
.177
.120
.120
.120
.120
-------
TABLE 1-4-4.3. C-GENERALIZED CURVE DATA FOR DENSE MEDIUM VESSEL BY SIZE FRACTION
Plus 4
c-Reduced
specific
gravity
.9399
.9457
.9487
.9496
.9612
.9690
.9787
.9903
.9923
.9932
.9961
1.0010
1.0078
1.0175
1.0271
1.0368
1.0465
1.0562
1.0659
1.0756
inches
Ratio
to
clean
1.000
.997
.993
.980
.700
.500
.260
.012
.006
.003
.000
.000
.000
.000
.000
.000
.000
.000
.000
.000
4 inches by
c-Reduced
specific
gravity
.9104
.9221
.9320
.9437
.9506
.9584
.9653
.9810
.9859
.9957
1.0045
1.0075
1.0153
1.0242
1.0359
1.0369
1.0379
1.0389
1.0399
1.0408
2 inches
Ratio
to
clean
1.000
.989
.977
.959
.945
.919
.800
.500
.400
.210
.040
.027
.013
.005
.000
.000
.000
.000
.000
.000
2 inches by
c-Reduced
specific
gravity
.8719
.8737
.9205
.9394
.9553
.9682
.9731
.9811
.9930
1.0059
1.0208
1.0258
1.0357
1.0476
1.0575
1.0774
1.0784
1.0794
1.0804
1.0814
1 inch
Ratio
to
clean
1.000
.993
.978
.962
.940
.906
.844
.700
.500
.288
.068
.048
.030
.015
.009
.000
.000
.000
.000
.000
1 inch by
c-Reduced
specific
gravity
.7828
.9322
.9474
.9595
.9666
.9757
.9908
1.0100
1.0353
1.0555
1.0656
1.0807
1.0938
1.1161
1.1272
1.1282
1.1292
1.1302
1.1312
1.1322
1/2 inch
Ratio
to
clean
1.000
.993
.987
.976
.954
.860
.700
.500
.247
.046
.025
.013
.007
.001
.000
.000
.000
.000
.000
.000
Minus 1/2
c-Reduced
specific
gravity
.8434
.8629
.8887
.9207
.9485
.9712
.9867
.9898
1.0104
1.0310
1.0527
1.0640
1.0722
1.0826
1.1083
1.1393
1.1702
1.2114
1.2372
1.2753
inch
Ratio
to
clean
1.000
.997
.991
.975
.956
.931
.899
.880
.690
.500
.300
.208
.160
.120
.071
.040
.020
.006
.002
.000
-------
TABLE 1-4-4.4. C-GENERALIZED CURVE DATA FOR DENSE MEDIUM CYCLONE BY SIZE FRACTION
Ul
Plus 1/2
c-Reduced
specific
gravity
. 94.1 3
.9502
.9602
.9652
.9681
.9691
.9950
1.0179
1.0199
1.0229
1.0278
1.0358
1.0448
1.0547
1.0647
1.0725
1.0736
1.0746
1.0756
1.0766
inch
Ratio
to
Clean
1.000
.997
.990
.983
.978
.970
.500
.066
.054
.040
.030
.020
.012
.006
.002
.000
.000
.000
.000
.000
1/2 inch by
c-Reduced
specific
gravity
.9069
.9148
.9297
.9396
.9475
.9644
.9574
.9/42
.9890
1.0038
1.0216
1.0236
1.0286
1.0385
1.0513
1.0632
1.0642
1.0652
1.0661
1.0671
3/8 inch
Ratio
to
clean
1.000
.997
.991
.985
.978
.970
.952
.940
.500
.220
.040
.029
.019
.008
.002
.000
.000
.000
.000
.000
3/8 inch by
c-Reduced
specific
gravity
.8939
.9315
.9415
.9474
.9543
.9563
.9712
.9910
1.0059
1.0217
1.0237
1.0277
1.0386
1.0524
1.0653
1.0812
1.0822
1.0832
1.0842
1.0851
1/4 inch
Ratio
to
clean
] .000
.992
.987
.982
.973
.968
.760
.500
.280
.056
.044
.034
.020
.010
.005
.000
.000
.000
.000
.000
1/4 inch by
c-Reduced
specific
gravity
.8761
.8891
.8991
.9141
.9441
.9590
.9670
.9790
.9990
1.0140
1.0300
1.0390
1.0539
1.0739
1.0989
1.1289
1.1389
1.1578
1.1588
1.1598
8 mesh
Ratio
to
clean
1.000
.999
.998
.996
.988
.979
.965
.800
.500
.320
1120
.088
.062
.04o
.024
.010
.006
.000
.000
.000
8 mesh by
c-Reduced
specific
gravity
.8458
.8763
.8967
.9181
.9426
.9599
.9731
.9782
.9823
.9986
1.0190
1.0496
1.0567
1.0771
1.0954
1.1229
1.1617
1.1973
1.2452
1.3247
14 mesh
Ratio
to
clean
1.000
.997
.994
.986
.969
.951
.928
.914
.896
.720
.500
.194
.156
.100
.073
.050
.029
.016
.006
.000
Minus 14
c-Reduced
specific
gravity
.8076
.8336
.8701
.8857
.9378
.9639
.9795
.9899
.9951
1.0160
1.0420
1.0785
1.0889
1.0941
1.1045
1.1358
1.1723
1.3546
1.5703
1.5713
mesh
Ratio
to
clean
1.000
.996
.988
.983
.958
.937
.917
.897
.880
.710
.500
.206
.130
.110
.089
.055
.036
.014
.000
.000
-------
TABLE 1-4-4.5. C-GENERALIZED CURVE DATA FOR HYDRO CYCLONE BY SIZE FRACTION
Minus 4
c-Reduced
specific
gravity
.5670
.5994
.6383
.6699
.6958
.7128
.7371
.7476
.7630
.8100
.8262
.8570
.9185
.9437
.9769
1.0368
1.1057
1.1988
1.2798
1.3770
mesh
Ratio
to
clean
1.000
.991
.965
.930
.890
.857
.793
.758
.702
.500
.440
.339
.153
.109
.074
.034
.017
.007
.003
.000
4 mesh by I
c-Reduced
specific
gravity
.5052
.5894
.6652
. 7241
.7578
.7999
.8420
.8715
.9052
.9262
.9649
1.0045
1.0390
1.0794
1.1687
1.3135
1.3977
1.5139
1.5148
1.5156
3 mesh
Ratio
to
clean
1.000
.962
.908
.835
.768
.646
.500
.400
.298
.247
.175
.115
.070
.048
.029
.012
.004
.000
.000
.000
8 mesh by
c-Reduced
specific
gravity
.3875
.4520
.4951
.5467
.5984
.7103
.7964
.8352
.8610
.9041
.9213
.9514
1.0117
1.0616
1.1064
1.1451
1.2269
1.3561
1.5068
1.6359
14 mesh
Ratio
to
clean
1.000
.981
.965
.939
.905
.971
.678
.595
.500
.332
.277
.221
.It
.095
.067
.053
.035
.017
.003
.000
14 mesh by
c-Reduced
specific
gravity
.2868
.3633
.4589
.5507
.5908
.6682
.7648
.8528
.8986
.9560
1.0267
1.0516
1.1013
1.1453
1.2237
1.2638
1.3002
1.7151
2.2179
2.2275
28 mesh
Ratio
to
clean
1.000
.989
.968
.941
.925
.881
.806
.713
.640
.500
.326
.279
.200
.140
.063
.041
.030
.011
.000
.000
28 mesh by
c-Reduced
specific
gravity
.3491
.4565
.5553
.6659
.8055
.8485
.9022
.9419
.9612
1.0740
1.3210
1.3339
1.3694
1.4016
1.4306
1.4499
1.5057
1.6916
2.0406
2.0513
65 mesh
Ratio
to
clean
1.000
.995
.983
.954
.886
.858
.814
.769
.735
.500
.094
.078
.049
.033
.024
.020
.017
.012
.000
.000
65 mesh by
c-Reduced
specific
gravity
.5635
.6127
.6738
.8441
.9508
.9844
.0096
1.0479
1.0791
1.1990
1.2482
1.2913
1.3549
1.5143
1.5587
1.6103
1.6546
1.8117
1.9184
2.0383
100 mesh
Ratio
to
clean
1.000
.999
.994
.954
.910
.891
.873
.838
.793
.500
.381
.313
.246
.212
.093
.069
.053
.021
.009
.000
Minus 100
c-Reduced
specific
gravity
.6810
.8513
1.1577
1.1791
1.1918
1.2054
1.3620
1.3892
1.4097
1.4369
1.4710
1.4932
1.5731
1.6072
1.6276
1.6548
1.7025
1.7910
1.8728
1.8741
mesh
Ratio
to
clean
1.000
.985
.890
.876
.863
.844
.500
.440
.400
.361
.321
.295
.230
.205
.193
.179
.157
.123
.100
.100
-------
TABLE 1-4-4.6. C-GENERALIZED CURVE DATA FOR SINGLE-STAGE BAUM JIG BY SIZE FRACTION
Plus 3
c-Reduced
specific
gravity
.8432
.8488
.3526
.3601
.8836
.9137
.9400
.9739
.9908
.9936
.9983
1.0058
1.0152
1.0293
1.0340
1.0406
1.0415
1.0425
1.0440
1.0449
inches
Ratio
to
clean
1.000
.997
.987
.979
.880
.699
.500
.223
.080
.064
.047
.032
.019
.006
.003
.000
.000
.000
.000
.000
3 inches by
c-Reduced
spec Lf ic
gravi ty
.8463
.8529
.8606
.9015
.9120
.9225
.9292
.9530
.9730
.9787
.9892
.9987
1.0159
1.0340
1.0454
1.0559
1.1131
1.1741
1.1750
1.1760
1-5/8 inches
Ratio
to
clean
1.000
.998
.990
.907
.869
.814
.750
.500
.300
.250
.20]
.169
.129
.097
.083
.075
.035
.000
.000
.000
1-5/8 inches by
c-Reduced
specific
gravity
.8056
.8328
.8570
.8882
.8993
.9053
.9637
1.0070
1.0523
1.0916
1.0976
1.1087
1.1248
1.1409
1.1651
1.2739
1.4551
1.7522
1.7532
1.7542
1/2 inch
Ratio
to
clean
1.000
.997
.991
.977
.967
.955
.699
.500
.299
.131
.113
.093
.075
.065
.057
.034
.015
.000
.000
.000
1/2 inch by
c-Reduced
specific
gravity
.7999
.8248
.8486
.8767
.9016
.9156
1.0-J97
1.0810
1.1761
1.1380
1.2096
1.2453
1.2364
1.3318
1.4118
1.5329
1.6788
1.8377
1.8388
1.8399
1/4 inch
Ratio
to
clean
1.000
.997
.989
.971
.945
.922
.681
.500
.275
.255
.229
.197
.169
.145
.115
.086
.061
.040
.040
.040
1/4 inch by
c-Reduced
specific
gravity
.7093
.7467
.7904
.8258
.8528
.8798
.8986
.9568
1.0400
1.1055
1.1710
1.1960
1.2158
1.2501
1.2958
1.3624
1.4414
1.5558
1.7763
2.0800
8 mesh
Ratio
to
clean
1.000
.995
.985
.970
.952
.931
.899
.733
.500
.366
.255
.217
.194
.168
.142
.144
.088
.062
.028
.000
8 mesh by
c-Reduced
specific
gravity
.7653
.7891
.8086
.8302
.8453
.8691
.9275
.9751
1.0810
1.1264
1.1448
1.1718
1.2129
1.2734
1.4745
1.5372
1.6129
1.7318
1.8982
2.0539
14 mesh
Ratio
to
clean
1.000
.996
.990
.980
.969
.937
.840
.739
.500
.397
.369
.337
.397
.250
.119
.089
.064
.038
.018
.010
Minus 14
c-Reduced
specific
gravity
.7656
.7968
.8385
.8880
.9374
.9635
1.0156
1.1497
1.3020
1.3619
1.3853
1.4244
1.4921
1.6171
1.7421
1.9400
2.1848
2.6040
2.6043
2.6066
mesh
Ratio
to
clean
1.000
.998
.990
.975
.948
.925
.873
.702
.500
.422
.400
.376
.343
.298
.267
.229
.193
.143
.143
.143
-------
4.5 Two-Stage Washing
The two-stage washing unit operation is closely related to the
single-stage operation. It differs only in that three output flows rather
than two are produced. The three output flows will be referred to as clean
(denoted with a subscript C) , middling (denoted with a subscript M) , and
refuse (denoted with a subscript R) . The mathematical approach differs in
C
that there are two sets of distribution curves used - d the proportion
s > g j
of each specific gravity and size fraction category in the feed which goes
M
to clean, and d , the proportion of each category in the feed which goes
S 5 g
to middling.
C M
Given the values for d and d the calculations of the values
s,g s,g
for the output flows are very similar to those given for the single-stage
operation. They are shown in the equations in (1) and (2).
F = dC FT
C,t,s,g s,g I,t,s,g
F = dM F
M,t,s,g s,g I,t,s,g
Fp = (1 - dC - dM ) FT
R,t,s,g s,g s,g I,t,s,g
C = C
C,t,s,g I,t,s,g
CMts2=CItse
11, L,S,g _L , L , S , g
C = C
R,t,S,g I,t,S,g
T = I s,g C,l,s,g
C E F
s,g
I s,g M,
M I F
s,g
WR = WI - WC -
57
-------
These equations make the percent moisture levels of each of the three output
flows equal to those of the input flow. To modify this the user may specify
two decision variables, D2 and D3, representing the percent moisture of the
clean flow and the percent moisture of the middling flow, respectively. Then
TT D2 E F0 1
wr = s,g C,l,s,g
(100 - D2)
D3 I FM .
w = s,g M,l,s,g
WM (100 - D3)
= W _ W _ TJ
R I C M
Note, as before, that the characteristic values of the three output flows are
identical to each other and to those of the input flow. Thus, two-stage
washers are assumed to have characteristic invariance.
C M
The values for the distribution curves, d and d , are the same
s,g s,g'
as they were for the washers. They were originally defined in Gottfried
f Q\
and Jacobsen as generalized distributions based on reduced specific
gravity computed from the decision variable value for specific gravity of
separation. In the present version of the program, they may either be
explicitly defined or may be derived generally from c-generalized distribu-
tion curves.
The only two-stage washing equipment type for which c-generalized
curve estimates are available is the two-stage baum jig. The c-generalized
£
curve values of d for the two-stage baum jig are identical to those given
s >§
for d for the single stage baum jig in the previous part on Table 1-4-4.6.
S'g M
The c-generalized curve values for d for the two-stage baum jig are given
s > §
in Table 1-4-5.1. It should be observed that the original formulation for
the middling stream from the two-stage baum jig was considerably more complex
than the present one. The values in Table 1-4-5.1 were derived from two
independent generalized curves in the original version of the program through
58
-------
TABLE 1-4-5.1. C-GENERALIZED MIDDLING CURVE DATA FOR TWO-STAGE BAUM JIG BY SIZE FRACTION
Plus 3
c-Reduced
specific
gravity
.8296
.8345
.8538
.8667
.8850
.8957
.9086
.9301
.9709
.9988
1.0267
1.0740
1.1234
1.3814
1.2297
1.2845
1.3898
1.5347
1.6840
2.0406
inches
Ratio
to
middling
.0000
.0017
.0101
.0216
.0507
.0922
.1906
.3315
.4707
.5475
.5645
.5000
.4370
.3800
.3450
.3160
.2730
.2330
.1980
.1320
3 inches by 1-5/8 inches
c-Reduced
specific
gravity
.8249
.8435
.8719
.8927
.9058
.9190
.9408
.9638
1.0940
1.1224
1.1618
1.2078
1.2800
1.4003
1.5863
1.9003
2.1880
2.1891
2.1902
2.1913
Ratio
to
middling
.0000
.0000
.0166
.0426
.0658
.0896
.1837
.3331
.4573-
.4425
.4314
.4000
.3620
.3090
.2430
.1490
.0680
.0680
.0680
.0680
1-5/8 inches
c-Reduced
specif i c
gravity
.8173
.8452
.8731
.9009
.9242
.9404
1.0542
1.1610
1.1749
1.2028
1.2376
1.3050
1.3862
1.5441
1.8274
2.3220
2.3232
2.3243
2.3255
2.3266
by 1/2 inch
Ratio
to
middling
.0000
.0021
.0095
.0245
.0619
.1097
.3734
.4266
.4258
.4189
.4020
.3738
.3439
.2950
.2274
.1188
.1188
.1188
.1188
.1188
1/2 inch by 1/4 inch
c-Reduced
speci fie
gravity
.7948
.8301
.8437
.8618
.9185
.9560
1.0342
1.1340
1.1884
1.2100
1.2599
1.3290
1.3926
1.4878
1.5574
1.8144
2.0412
2.2680
2.2691
2.5678
Ratio
to
middling
.0000
.0000
.0040
.0150
.0799
.1354
.2679
.3680
.3883
.3834
.3576
.3304
.3168
.3011
.2904
.2583
.2355
.2036
.2034
.1748
1/4 inch by
c-Reduced
specific
gravity
.7187
.7399
.7632
.7950
.8247
.8533
.8798
.8946
.9031
.9964
1.0600
1.1024
1.1702
1.1989
1.2444
1.3123
1.3685
1.4946
1.6960
2.1200
8 mesh
Ratio
to
middl ing
.0000
.0030
.0070
.0150
.0270
.0430
.0650
.0840
.1010
.3400
.5000
.5770
.6870
.7170
.7480
.7860
.8090
.8510
.8910
.9370
8 mesh by
c-Reduced
specific
gravity
.7970
.8192
.8369
.8480
.8568
.9686
1.1070
1.1646
1.2077
1.2553
1.3173
1.3981
1.5155
1.6516
1.8277
2.0491
2.2140
2.2151
2.2.62
2.2173
14 mesh
Ratio
to
middling
.0000
.0050
.0120
.0200
.0310
.2410
.5000
.6000
.6590
.7090
.7590
.8050
.8500
.8830
.9050
.9200
.9250
.9250
.9250
.9250
Minus 14 m
c-Reduced
specific
gravity
.8016
.8350
.8631
.9325
1.0154
1.0568
1.1075
1.2318
1.3360
1.3894
1.4656
1.5711
1.7128
1.8811
2.0775
2.6720
2.6733
2.6747
2.6760
2.6773
esh
Ratio
to
middling
.0000
.0050
.0150
.0530
.1030
.1350
.1750
.3590
.5000
.5510
.5950
.6770
.6790
.7170
.7520
.8400
.8400
.8400
.8400
.8400
-------
a series of relatively complex computations. These are not directly relevant
to this discussion and will not, therefore, be discussed here. The point is
brought up only because as a result of these transgenerations of two genera-
lized curves into one c-generalized curve, the c-generalized version produces
slightly different results than did the original version. These differences
do not appear to be significant.
60
-------
4.6 Froth Flotation
Perhaps the most interesting of the unit operations is the one
for froth flotation. As mentioned in Chapter 3 of this section, froth
flotation is unique in that the unit operation has the property of character-
<
istic invariance, but does not have the property of characteristic
independence. Reviewing these concepts briefly, the above means that though
the values of C for the output flows are the same as those of the input
t 5 S , g
flows, the determination of the distribution of the material in the output is
dependent upon the values of C in the input. This topic is expanded in
t, s , g
the following discussion.
In the final analysis, the froth flotation unit operation is much
like that of the washing unit operation in that it computes a set of values,
d , called distribution curves which specify the proportion of each speci-
s >§
fie gravity and size fraction category in the input flow (denoted by a
subscript I) which will go to the clean output flow (denoted by a subscript C)
The remaining material in the input flow goes to a refuse output flow (denoted
by a subscript R). Given the values for d , the calculations for the output
8 > §
flows as shown in (1) and (2) below are identical to those for the washing
unit operation.
^ = d F
C,t,s,g s,g
t s g s e I t s
JL5t)56 & 5 & J- » L > ^ >
C = C
C,t,s,g I,t,s,g (1)
C = C
R,t,s,g I,t,s,g
TJ = I s,g C,l,s,j
C - FT ,
s,g I,l,s,g
WR = WI - WC
61
-------
If the user supplies a decision variable, Dl, representing the percent moisture
of the clean output flow, then
Dl £ Fn
„ = s.g C.l.s.g
WC (100 - Dl)
(2)
WR = wz - wc
The remainder of this part discusses the derivation of the values for d
s,g
for the froth flotation unit operation.
The only discussion of this unit operation to date appears in
Gottfried, Jacobsen, and Vaillant and states:
"The overall yield of clean coal is taken as the value of the
cumulative weight distribution in the froth flotation feed at a
specific gravity of 1.50. Similarly, the overall ash content of
the clean coal is taken as the cumulative ash of the feed at a
specific gravity of 1.60. Detailed specific gravity analyses
of the clean coal and refuse products are obtained by applying
to the feed a distribution curve that will produce the
'1.50-yield/1.60 ash' product. Sulfur and Btu content of the
products are obtained from the distribution curve calculations
and may differ from the amounts present in either the 1.50 or
1.60 specific gravity feed level."
This description of the unit operation is a bit complex and can be made more
understandable by a specific example.
Flowstream number 17 of the example, shown on page 35 of Appendix A
(p. 188), is the input flowstream to the froth flotation cell. Flowstream
number 21 of the example, shown on page 45 of Appendix A (p. 198), is the clean
output flowstream from the same froth flotation cell. Note that the cumula-
tive weight percent is 66.16 percent for the composite size fraction of the
input flow for the specific gravity fraction whose upper bound is 1.50. Also
note the cumulative percentage of ash (4.63 percent) for the composite size
>
fraction for the specific gravity fraction whose upper bound is 1.60. Applying
the description given earlier then, the yield from the froth flotation cell
should be approximately 66.16 percent and the overall percent ash in the clean
output flow should be approximately 4.63 percent.
62
-------
Moving over to flowstream 21, the clean output flow, the overall
percent ash is 4.7 percent. This value is the bottommost value in the cumula-
tive percent ash column. Turning to the summary data for Units 13, page 44 of
Appendix A (p. 197), the yield percent for the froth flotation cell is 65.7
percent as indicated.
Actually within the program the "1.50 yield/1.60 ash" rule is not
applied to the composite flow, but rather is applied to the individual
size fractions. The example printouts verify that for each size fraction
the relationship described above holds.
The only remaining problem for the froth flotation unit operation
then is to produce a distribution curve for each size fraction such that the
yield of clean coal for that fraction equals the cumulative weight in the
feed at a specific gravity of 1.50 for that size fraction and the ash content
of the clean coal in that size fraction equals the cumulative ash of the feed
at a specific gravity of 1.60 for that fraction. To accomplish this, the
froth flotation unit operation is given access to a set of raw generalized
distribution curves—those for the concentrating table. The adjective raw
is used to indicate that the adjustment factors and size fractions specifica-
tion associated with the generalized distribution curves are completely
ignored. Table 1-4-6.1 shows the actual value for these curves.
To generate a particular distribution curve requires estimating a
value of specific gravity of separation and then using it to compute a set of
reduced specific gravities. The algorithm itself produces every distribution
curve from the seven generalized curves in Table 1-4-6.1 for every possible
specific gravity of separation between 1.40 and 1.60 in steps of .01, for
every size fraction. It then uses that curve which comes closest to producing
the desired yield and percent ash.
63
-------
TABLE 1-4-6.1. RAW GENERALIZED DISTRIBUTION CURVES USED FOR FROTH FLOTATION UNIT OPERATION
Reduced Ratio
specific to
gravity clean
.828
.880
.890
.900
.914
.924
.933
.938
.953
.970
1.000
1.031
1.066
1.071
1.080
1.090
1.100
1.111
1.300
1.500
1.000
.993
.987
.978
.960
.940
.920
.900
.800
.690
.500
.300
.080
.060
• .043
.033
.026
.023
.011
.000
Reduced
specific
gravity
.834
.856
.870
.880
.890
.902
.910
.937
.949
.970
1.000
1.035
1.045
1.069
1.090
1.116
1.140
1.168
1.200
1.556
Ratio
to
clean
1.000
.997
.993
.987
.977
.963
.948
.900
.800
.675
.500
.300
.240
.180
.099
.060
.040
.026
.018
.000
Reduced
specific
gravity
.785
.850
.865
.885
.900
.920
.930
.975
1.000
1.050
1.080
1.095
1.120
1.150
1.200
1.260
1.700
1.800
1.900
2.000
Ratio
to
clean
1.000
.997
.994
.981
.960
.920
.880
.635
.500
.279
.148
.100
.068
.046
.025
.018
.000
.000
.000
.000
Reduced
specific
gravity
.759
.820
.830
.850
.865
.875
.890
.910
.930
1.000
1.070
1.090
1.120
1.160
1.205
1.325
1.475
1.669
1.800
2.000
Ratio
to
clean
1.000
.993
.991
.983
.972
.962
.939
.887
.817
.500
.246
.195
.145
.103
.073
.040
.015
.000
.000
.000
Reduced
specific
gravity
.731
.760
.780
.808
.840
.862
.900
1.000
1.120
1.160
1.200
1.260
1.300
1.360
1.600
1.800
2.000
2.050
2.100
2.150
Ratio
to
clean
1.000
.994
.987
.968
.932
.900
.800
.500
.200
.135
.099
.066
.052
.040
.026
.021
.020
.020
.020
.020
Reduced
specific
gravity
.663
.720
.780
.820
.862
.888
.916
1.000
1.026
1.040
1.079
1.120
1.220
1.240
1.270
1.320
1.380
2.000
2.050
2.100
Ratio
to
clean
1.000
.977
.941
.908
.862
.823
.758
.500
.420
.375
.300
.237
.100
.080
.060
.040
.030
.020
.020
.020
Reduced
specific
gravity
.606
.640
.680
.724
.760
.800
.836
.852
.900
1.000
1.060
1.124
1.200
1.320
1.400
1.600
2.000
2.050
2.100
2/150
Ratio
to
clean
1.000
.998
.992
.981
.969
.947
.919
.900
.800
.500
.400
.339
.292
.243
.219
.177
.120
.120
.120
.120
-------
4.7 Resizing Unit Operations
The three remaining unit operations to be discussed in this chapter
are rotary breaking, crushing, and dewatering. All three change the size
distribution of the feed stream - a general operation referred to as resizing
Before discussing the specific operations, the general concepts of resizing
are discussed. Much of the material is taken from Vaillant and Broadbent
and Callcott^ , though the actual approach described here differs from that
taken by either of the above.
In essence, there are four distinct processes which can take place
during the resizing operation:
(1) Liberation
(2) Selection of breakage
(3) Breakage
(4) Screening.
Various resizing operations differ not only in the mathematical distributions
associated with the processes, but also in the manner in which the processes
interact in order to achieve the ultimate end. This discussion deals primar-
ily with those processes as separate phenomena. Later parts of this chapter
will deal with their interaction as simulated in the two unit operations.
4.7.1 Liberation
The effect of the process of liberation is that daughter particles,
all broken from the same parent, do not have the same characteristics as
the parent. This does not imply, however, that the composite levels of the
various characteristics, often referred to as the mass balance, are not main-
tained during liberation. Equation (1) states this formally.
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F-C = E F -C
t a a t,a
where
F is the total weight of the parent
C is the value of characteristic t per weight unit for the
parent
a ranges over all daughters
F is the total weight of the otth daughter
C is the value of characteristic t per weight unit for the
t,a
ath daughter.
The liberation process is minimally modeled in the rotary breaking
unit operation and is ignored in the crushing unit operation. Formally, when
liberation is modeled, it is treated as though it preceded the remaining
resizing operations. The flow stream is first partitioned into the a parti-
tions and then each partition is resized independently.
4.7.2 Breakage and Selection for Breakage
A breakage process is that process which alters the size of some or
all of the particles in an assembly. The selection for breakage process is
that process which determines the proportion of particles in the assembly
which will undergo breakage. In their implementation within CPSM4, both break-
age and selection for breakage assume that all particles formed by the breaking
of a larger particle have characteristics identical to that larger
particle. Any effects of liberation are treated separately. The proportional
breakage of a particle of size Y into particles of size less than X is repre-
sented by the function B(X,Y). Broadbent and Calcott hold that
"differences between coals and between breakage processes are
accounted for, not by changes in B(X,Y) which is never altered,
but by taking different selection functions."
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The precise form of the breakage function proposed by the above is
shown in (2) below.
B(X,Y) = (1 - e~X/Y)/(l - e'1) (2)
The denominator of this function is, of course, a constant and is equal to
0.63212. This breakage function is used by Vaillant and in the program
to account for all of the breakage in the rotary breaker and some of it in the
crusher. Each crusher type is assigned its own breakage function in addition.
This is discussed in Part 4.9. The breakage that occurs in a dewatering
device is discussed in A.7.4.
4.7.3 Screening
The final process in the simulation of the rotary breakers and
crushers is screening. Once particles have been broken, they may or may not
be eligible for another pass through the selection and breakage processes.
This screening process is implemented using the same type of equation used
for the screens.
4.7.4 Prebreakage
The mathematics underlying the operation of dewatering is concerned
mainly with the breakage that occurs as a secondary effect. To allow for the
possibility of secondary breakage during unit operations other than dewatering,
the secondary breakage is treated as a separate unit operation which is
performed prior to the primary unit operation in which no breakage takes place.
The formulation of this secondary breakage or prebreakage of the
input flow to a unit is similar in part to that of breakage described in 4.7.2
above. The basic principle is the concept of selection in which it is supposed
that any breakage process may be described by first defining the probability
of breakage of particles of each of the sizes involved, and then considering
the size distribution of all of the particles, both broken and unbroken. The
breakage function used is that of Broadbent and Callcott
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B(X,Y) = (1 - e X/Y)/(1 - e l) (1)
where B(X,Y) is the fraction of coal of initial size Y that is broken below
size X. The coal is selected for breakage by assuming that a certain fraction,
IT , of the coal in size fraction i is to be broken.
A.breakage matrix, b, can be obtained from the breakage function and
the grade sizes of the feed; the i-jth element of b is the proportion of the
feed which was in the jth size fraction before breakage and is in the ith size
fraction in the breakage product. To allow for more severe breakage, powers
Tr
of the breakage matrix may be used. We assume breakage according to b where
the integer K > 1. Then the prebreakage equations are
s
Fn = FT (1 - IT ) 4- Z F_ , TT , b . (2)
0,t,s,g I,t,s,g s' s?=1 I,t,s',g s' ss'
where the feed to the unit is denoted by subscript I and the flow after pre-
breakage is denoted by subscript 0.
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4.8 Rotary Breaking
The unit operation for rotary breaking is difficult to describe in
equation form. It will, therefore, be presented as a procedure, in a series
of steps. The basic decision variables for the rotary breaking unit operation
are the length of the drum in feet, the diameter of the drum in feet, and the
size of the drum opening in inches. In addition, the user must define
a series of empirical constants when he defines the rotary breaking equipment
type. These constants are specified in the following discussion.
The first step is to compute the number of falls that the streams
will undergo in the breaker and the height of each fall. The number of falls
equals the length of the breaker divided by a constant 1.3; while the height
is computed by multiplying the diameter by the constant 0.75. Both of these
constants are specified on the equipment type definition.
The second step is to compute the probabilities that material will
not pass through the holes of the breaker. This is computed using the stan-
dard screening equation .
pr(ss,ps) =
1.0 if ps >_ss
(1)
^-ACss)(1-ps/ss) . ,.
where
pr is the probability of not passing through the hole
ss is the hole size
ps is the particle
A is a constant based on the hole size
The value of A is 40 if the hole size is less than or equal to 7 inches,
otherwise it equals 50. These constants are all specified in the equipment
inventory.
The third step is to liberate the rock and coal streams from the
feed. The unit operation assumes that only the highest specific gravity
fraction in each size fraction contains any rocks. The weight of these rocks
is assumed to equal the weight of ash in the next to highest specific gravity
fraction. The rocks are assumed to contain sulfur and to have no Btu content.
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At this point the two streams - coal and rock - are treated
separately. Each takes the number of falls computed above. The material is
selected for breakage using a selection function which is a function of the
fall number. The rock and coal selection distributions are specified
separately. For rocks, the first fall has a selection value of .005; while
the remaining falls have values of 0.0. Thus, the rocks undergo little
breakage. The first 12 falls of the coal have a selection factor of 0.20.
The factor is 0.08 for the next 12, 0.06 for the next 12, and 0.05 for the
remaining falls. The breakage function used is the general one given earlier.
After each fall, some material passes through the holes and some does not.
This is calculated via the pr values calculated earlier.
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4.9 Crushing
The crushing unit operation actually consists of three separate
procedures. The material in the flow is divided into three fractions depend-
ing on its size as follows:
(1) The material larger than the crushing zone
(2) The material in the crushing zone
(3) The material below the crushing zone.
The crushing zone is that size range between the crusher setting and 1.7 times
the crusher setting. The crusher setting is the decision variable for the
unit and 1.7 is a constant specified by the user in the equipment type
specification.
All material larger than the crusher zone is broken into material
which is no larger than the upper bound of that zone. The breakage distribu-
tions used are specific to the crusher type. Table 1-4-9.1 shows these dis-
tributions along with the values of the general one proposed by Broadbent and
Calcott . The general curve is computed from the equation given earler.
The source of the crusher specific curves is unknown.
The material in the crushing zone is broken in accordance with the
general breakage distribution. The additional assumption is made that some
particles may slip through unbroken in accordance with the screening equation.
The screening constant is 8 for primary crushers and 2 for secondary crushers.
There is also a selection for breakage factor of .85. The smallest material
is as above without the slippage assumption.
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TABLE 1-4-9.1. CRUSHER BREAKAGE DISTRIBUTIONS
Size
ratio
1.0000
.8308
.5882
.4176
.2065
.1041
.0522
.0368
.026
.0131
.0000
General
distribution
1.0000
.8927
.7035
.5400
.2952
.1564
.0805
.0572
.0406
.0206
.0000
Multiple
roll
crusher
1.0000
.9500
.8500
.6500
.3500
.2200
.1400
.1100
.0900
.0300
.0000
Gyratory
/jaw
crusher
1.0000
.9500
.8500
.7000
.3500
.2000
.1900
.1700
.1200
.0800
.0000
Single
roll
crusher
1.0000
.9600
.7900
.4500
.2000
.1000
.0500
.0300
.0200
.0000
.0000
Primary
cage mill
crusher
1.0000
.8400
.5000
.3200
.1500
.0520
.0190
.0110
.0066
.0020
.0000
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4.10 Dewatering
The mathematics of dewatering is concerned with the splitting of
the input flow into two output flows, one of which consists mainly of water.
As a secondary effect breakage occurs during the operation of the dewatering
device. Thus the unit operation of dewatering can be treated simply as a
splitting operation combined with prebreakage. These operations are described
in 4.2 and 4.7.4.
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5.0 THE COMPUTATION OF COST
This chapter describes the cost computation component of program
CPSM4. In essence the purpose of this component is to model the economics
of the coal preparation process. In particular, this component is intended
to estimate that per unit price at which the material in the salable output
flows must be sold so as to meet the costs required to Droduce those flows.
Those costs, of course, include a reasonable, user specified, rate of return
on the investment made to establish the configuration. The cost component
is implemented within CPSM4 so that the combined capabilities of the process
simulation component and the cost component can be used to perform detailed
performance-cost trade-off studies for the coal preparation process.
There were several major problems encountered during the attempt
to interface a cost computation procedure with the process simulation. Most
importantly, as was discussed in part 1-2.0, the process simulation is expli-
citly assumed to be steady-state. The behavior of the system being simulated
is assumed not to vary as a function of time. This assumption, though simpli-
fying, appears to cause no major inaccuracies in the results of the process
simulation. Unfortunately, any reasonably sophisticated approach to the
estimation of the costs associated with a project must deal with the notion
of cash flows. These cash flows vary dramatically through the life of a
project—construction, operation, and shutdown; therefore, they must be char-
acterized as time series. The steady-state assumption cannot be maintained
in the cost computation component.
The second problem encountered has to do with relating the cost
computations to the units and flows in the configuration simulated by the
process component. Obviously, many of the costs such as price of raw coal,
price of equipment, and operating labor, relate directly to the units and
flows; however, many other costs, such as price of land, transportation costs,
and administration, do not relate directly to the elements in the configuration,
Even those costs which do bear on the units and flows in apparently straight-
forward ways, require that the configuration be sized before they can be
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calculated. The reader is reminded that the process simulation estimates all
flowrates simply as a percent of feed or as tons per hour. There is no infor-
mation as to how much material is being processed over the life of the
configuration. This information is critical if the configuration is to be
costed.
Expanding the above point slightly, once a given configuration has
been simulated, there are potentially many different cost scenarios which
might be calculated. The following represent some of the different types of
questions which the user might wish to ask:
(1) How does the selling price vary as the overall
output capacity of the configuration varies?
(2) How does the selling price vary as the purchase
price of various elements needed varies?
(3) How does the selling price vary as a function
of the desired level of rate of return on
investment?
The number of combinations of questions which might be asked is extremely
large. If the entire process simulation had to be executed on the computer
separately for each costing scenario, then the computer resources required
by CPSM4 might well become prohibitive.
The basic conclusion drawn as a result of the above types of issues
was that the cost computation component should not be structured as an
integral part of the process simulation component; rather it should be
implemented as a post-processing step. Physically, at that point in time
in the computer program, the following information is available:
(1) The equipment inventory
(2) The description of the configuration
(3) The summary data for flowstreams.
The most important of these is the summary data for flowstreams which includes
the following composite information for each flowstream in the configuration:
(1) Flow rate as a percent of total feed
(2) Percent by weight of flow which is ash
(3) Percent by weight of flow which is pyritic sulfur
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(4) Percent by weight of flow which is total sulfur
(5) Average Btu per pound.
The information which is no longer available to the program once the process
simulation has completed its work includes the following:
(1) The detailed size and specific gravity analyses of
the flowstreams, and
(2) The detailed performance characteristics of the units.
The fundamental assumption, then, made in the implementation of the cost
component is that the costs associated with the establishment and operation
of a coal preparation configuration do not vary as a function of the detailed
characteristics of either the flowstreams or unit performances. This assump-
tion is clearly a simplifying one. No attempt will be made in this presen-
tation to justify this assumption. It is taken as given.
As will be described in more detail later, a major benefit is
derived from implementing the cost computation component in program CPSM4
as a post-processing step. The cost component may be used indenendently of
the process simulation. If the user merely wishes to estimate the costs
associated with an arbitrary project, he can use CPSM4 to perform the calcu-
lations. It must be emphasized, however, that the complete power of the cost
component is realized only via the use of it in conjunction with the process
simulation component.
In addition to the information needed to execute the process simu-
lation, if the user is executing that component, he must provide the cost
component with an inventory of the basic cost elements to be considered. The
values of these elements may be
(1) Constant
(2) Functionally related to the summary data for some flowstream
(3) Functionally related to other cost elements or sums of
cost elements.
The manner in which these are defined is described later in this volume.
Based on the configuration data and on the cost element inventory,
the user may run many different costing scenarios as described briefly earlier
in this part. The basic interface between the disaggregated information
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described above and the actual procedures which calculate the capital costs
and which take into account the desired rate of return on investment is the
project cash flow description. This cash flow description is a time series
specification of the aggregated annual cash flows required to construct the
configuration and to operate it over its entire life. The content and use
of this project cash flow description is discussed in the next part.
5.0.1 An Example Project to be Costed
The following discussion will be persented in terms of the Cost
Component Example presented in part 2.2. The actual results for this example
are presented in Appendix B.
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5.1 Measuring Profitability
As was stated in the introduction to this chapter, the goal of the
cost computation algorithm in program CPSM4 is to estimate that per unit
selling price of the output flows of coal which will exactly recoup the costs
incurred in producing those flows and which will guarantee a certain level
of profit, or rate of return on investment, for the investment capital. To
take the desired level of profit into account is by far the most difficult
part of the computation. The method used in program CPSM4 for measuring
profitability is the discounted cash flow method.
5.1.1 The Project Cash Flow Description
To measure the profitability of some project requires a description
of all capital and operating expenditures and of all earnings on an annual
basis over some period of time. The normal period of time used is the entire
life of the project from the beginning of construction through the end of
operation when the project is closed down and the working capital is withdrawn.
Though nothing in the following discussion requires that the user measure
profitability over the entire life of the coal preparation plant, this is the
normal convention and to simplify the discussion it will be assumed.
The set of values which describes the project expenditures and
income will be referred to as the "project cash flow description", or simply
CFD. Each of the measures of profitability is predicated primarily on the
project CFD along with various other overall parameters specifying such things
as the desired level of profitability, the income tax rate, etc. The first
step, then, in describing the measurements of profitability consists of
explaining the content of the project CFD. To serve as an example for this
explanation the User Handbook Cost Example, page 10 of Appendix B, (p. 233) shows
a CFD. The source of this table is Holt(5) which was presented in part 2.2.
As can be seen on this page, the first column in the project CFD
is the year time value. The normal convention is that the plant goes into
production at the beginning of year 1, though it need not be in full produc-
tion at that time. The last year of construction and start-up occurs during
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year 0 and so back to year -1, -2, to the start of production. The example
shown has a construction period of 1 year and an operational life of 10 years.
The second column in the project CFD is the annual production. The
purpose of this column is to serve as a basis for the computation of gross
annual income. Remember that the purpose of the cost computation is to measure
the selling price. This price multiplied times annual production would give
the gross annual income. The entries in this column will always be zero during
the construction and start-up periods and will typically be constant during
the operational period except for the first and last years. This level of
production value would typically come from the flowstream summary report data
of the process simulation component of the program. The user would specify
the amount of feed and using the flowrate (percent of feed) values, CPSM4 would
compute the amount of output. In this case the program is told that the total
annual feed to the plant is 1.56 million tons of coal. Thus the annual
production of clean coal is as shown below:
1.56 x 10 /600 x 363.9 = 946,140 tons per year.
In this case 600 is the hourly feed to the plant in tons, while 363.9 is the
hourly clean output flow, in tons, from the plant (see flowstream number 26 on
page 6 of the User Handbook Cost Example, Appendix B [p. 229]).
The third column in the cash flow description is the amount of
capital investment which may be depreciated. Included in this column is the
cost of equipment, the cost of buildings, and so on. If some component of the
above has a salvage value, then only the difference between the total cost and
the salvage value would be entered in this column. In the case of the example,
the figure of 3.94 million dollars comes directly from the total capital require-
ment figure on page 8 of Appendix B (p. 231). There the figure was computed
by summing the various components listed in the cost element description.
The fourth column in the CFD is the nondepreciable capital invest-
ment column. This column contains the cost of land, the amount of working
capital needed, and the salvage values of depreciable capital costs. Note
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that the negative of the total nondepreciable capital investment should be
entered for the last year of operation. This entry reflects the withdrawal of
working capital, land, and salvage by the investors at the end of the project.
In the present example, Holt gave no information as to the levels of nonde-
preciable capital needed; therefore, they were assumed to be zero.
The fifth column in the project cash flow description contairis the
annual operating costs. It includes such things as the cost of raw materials
and utilities, labor and maintenance costs, administration and overhead costs,
etc. Overall, it includes all costs incurred to produce and sell the product,
other than capital costs. It may include various negative elements reflecting
byproduct credits. It does not include depreciation, other income tax
credits, or income tax payments. In the case of the example, the annual
figure of 2.48 million dollars comes directly from page 9 of Appendix B (p. 232)
The sixth column in the project cash flow description is depreciation.
Though the values for depreciation may be explicitly entered into the CFD by
the user via the cost elements, the depreciation is normally calculated by the
program from the value of the depreciable capital investment. To perform this
calculation, CPSM4 assumes straight-line depreciation over the life of the
proj ect.
The seventh column in the project cash flow description is other
tax allowances. In the present example, these are assumed to be zero.
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5.2 The Discounted Cash Flow Analysis
Once the project cash flow description has been completed, the
calculation of the discounted cash flow analysis, or DCF, can be made. The
only additional information which must be supplied by the user is the desired
rate of return on investment and the tax rate to be applied to earnings. The
purpose of the DCF analysis is to estimate that per unit price at which the
material in the salable output flows must be sold so as to meet- the costs
required to produce those flows, including a desired rate of return on invest-
ment .
The key notion about which the DCF analysis revolves is the discount
factor (also known as present worth factor) shown in column 6 on page 11 of the
User Handbook Cost Example, Appendix B (p. 234). The present value, P, of a future
sum of money, F, is given by
P = F x dfc
where d = l/(l+i) is the discount factor in the .t-th year for rate i. By
multiplying annual cash flows times their corresponding discount factors, one
obtains the annual discounted cash flows. By definition the net present value
of a project is the sum of its discounted cash flows. The true rate of return
of a project is that value of i in the calculation of the discount factor which
makes the net present value over the entire life of the project equal to zero.
The purpose of the program then is to calculate that selling price which makes
the user-specified desired rate of return the true rate of return for the
project.
5.2.1 Basic Identities Used
This part defines the basic identities and definitions from which
the DCF procedure is derived. To simplify the following discussion, the
following notation will be used to represent the values in the CFD:
Y - the value of the t-th year
P - the annual amount of production in the t-th year
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CD - the annual amount of depreciable capital
t investment in the t-th year
CN - the annual amount of nondepreciable capital
*" investment in the t-th year
0 - the annual amount of operating expenses in the
t-th year
D - the annual amount of depreciation in the t-th year
A - the annual amount of other tax allowances in the t-th year.
The symbol, r, is used to denote the tax rate and the symbol, S, is used
to denote the per unit selling price for production. Note that these are
assumed to be a constant.
Taxable income, TI , is defined as follows:
TIt = S x Pfc - Ot - Dt - At .
Thus, it equals gross annual sales less operating expenses, depreciation, and
allowances. Note that it may be negative. This will often be true for projects
with heavy start-up expenses.
Taxes, TX , are defined as follows:
(TI x r if TI > 0
"
0 if TI <_ 0 .
Note that in this formulation no tax credits are estimated. This might well
be a valuable future enhancement.
Annual cash income after taxes, CI , is computed from
CIt = S x P -0 -TX
It equals gross sales less operating expenses and taxes.
Annual cash flow, CF , is defined as follows:
CF = CI - CD - CN
t t t t
It is annual cash income minus annual capital investment. Note that values of
CF may be positive or negative.
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The annual discounted cash flow, DF , is then
DFfc = CF x d
Here d is the annual discount factor presented earlier. Finally, NPV is
the net present value of the project; thus,
NPV = Z DF
t=l t
By definition, the project achieves the desired true rate of return
when the value of S is established so as to make NPV equal to zero.
On page 11 of Appendix B (p. 234), column one is t, two is TI ,
three is TX , four is CI , five is CF , six is d , and seven is DF . Note
L L t L t
that the sum of column seven is zero.
5.2.2 The Actual Procedure
The actual procedure for calculating S from the definitions in
the previous part would be straightforward it it were not for the calculation
of TX which is contingent on the value of S. Since this contingency is
present, a convergence approach must be used. Fortunately, the convergence
is well-behaved and the solution can be derived quickly.
The first step in the procedure is based on the assumption that
negative taxes are possible in the form of a net increase to cash income in a
given year. This assumption is obviously false; however, it gives a good first
guess, which is often the final result. The implementation of this assumption
is to define taxes simply as follows:
TX = TI x r .
Taxes equal taxable income times the tax rate for all incomes—even negative
ones.
Using this assumption, it is possible to solve for S.
NPV = I DF =0 (by definition)
E(CI - CD - CN ) x d (by substitution)
£ (S x P -0 -TI xr-CD -CN)xd =0 (by substitution)
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(S x Pt - S x Pt x r) x dfc = £ (Ot - Ot x r - Dfc x r - At x r
+ CD + CN ) x d
S = (l, [0 x (1-r) - Dfc x r - At x r + CDt + CNt]
([1-r] x E Pt x d
x
Now, in the case where TI is greater than zero for all t, this
estimate of S is the correct one as the assumption
TX = TI x r
is true for all t. The problem comes in those cases where TI is negative.
In these cases, the resultant NPV calculated on the first estimate of S will
be negative. Assume its value is NPV1. The procedure computes this value
and a new value of S as follows :
S1 = SQ - NPV /((1-r) x E Ptdt) .
This continues until the value of NPV' converges with zero.
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6.0 PREPARING THE INPUT
This chapter provides a detailed description of how to prepare and
code information for program CPSM4. The input data deck to the program consists
of six segments in this order:
(1) Run control
(2) Equipment inventory
(3) Configuration
(4) Feed description
(5) Configuration and feed selection
(6) Cost calculation description.
Each of the.se segments is discussed separately, in the above order except that
the run control segment is presented last.
The discussion of each begins with a formal description of the coding
procedures to be used followed by an informal discussion of those procedures.
Also included is a listing of and general comments about the actual input used
to generate the user handbook printouts. In addition to the parts of this
chapter describing the preparation of the input, other parts are included
which contain information of a more general nature.
All input is described as though it were being physically read into
the program in punch card form. This is done for convenience of reference
only. In fact, the input decks might well be maintained and input from some
general text editor available on the various computers. The only real restric-
tion is that the input be in coded card-image form.
The data for segments 2, 3, and 4 may be in coded card-image form,
or it may be read from feed and configuration data bases in which case these
segments are missing from the input data deck. If the data for those segments
is present in the data deck then two data bases are created storing that input
information. If those data bases are permanently saved at the end of the run,
then future runs may be made using the information directly from the data bases.
This greatly reduces the size of the input data deck needed.
The two data bases that are created are
(i) the configuration data base, stored on file unit 3, and
(ii) the feed data base, stored on file unit 4.
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The configuration data base contains the equipment inventory together with
up to thirty configuration specifications that employ that equipment inventory.
The feed data base consists of up to thirty feed descriptions, all of which
are assumed to have the same numbers of size fractions and specific gravity
fractions, and the same characteristics. Each configuration and each feed is
identified by a unique key supplied by the user. The keys are used to identify
and select the particular configuration and feeds that are to be used in a
given run.
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6.1 General Coding Conventions
All of the information entered into the program via the input data
deck is organized on cards in fixed-field form. There are various conventions
associated with fixed-field input, which derive from the interaction of various
FORTRAN FORMAT rules and from the particular manner in which these are imple-
mented in this program.
Most fundamental is the notion of the character set. All infor-
mation entered into the program is written and then punched onto cards.
The particular characters which may be used in writing this input are limited
to those which can be recognized or accepted by the program. The entire
group of these is the character set accepted. The character set accepted
by this program consists of the following 47 characters:
(1) The numeric characters (0-9)
(2) The alphabetic characters (A-Z)
(3) Special characters (+-*/=()$. , b).
Note that the symbol b^ is used to indicate a blank. All alphabetic charac-
ters are upper case. This character set, though admittedly limited, is more
than sufficient to meet the needs of this program.
At the next conceptual level above that of the character set is
the notion of the field. A field is defined as a set of contiguous character
positions on an input record. The character positions on the input records,
which are typically referred to as columns, are numbered consecutively from
1 to 80 from left to right. Within the coding instructions fields will typi-
cally be defined in terms of their inclusive beginning column number and
ending column number. The basic characteristics of a field is its width. The
width of a field equals its ending column number minus its beginning column
number plus 1. Thus, an eight character field beginning in column 10 would
end in column 17; or conversely, a field beginning in column 10 and ending
in column 17 would be an eight character field.
Information being entered into fields will be referred to as being
right-justified or left-justified. Information is right-justified in a field
if the last nonblank character appears in the ending column defined for that
87
-------
field; and information is left-justified if the first nonblank character
appears in the beginning column of the field. These notions of right and
left justification are especially important as they relate to the coding of
numeric information.
Since most of the information being entered into the program is
numeric and is being processed under the control of FORTRAN FORMAT specifica-
tions, a brief description of the general conventions associated with the
entry of numeric data for processing of the above type is needed. The basic
problem is that all blanks within a fixed numeric field are interpreted as
though they were zero. This is a universal convention for all FORTRAN progams;
therefore, it is followed in this program. As will be discussed below, this
convention is a major source of error in the preparation of input to programs.
As an example, the entries — bb!23, b!23b, 123bb — when entered
into a five character field would be interpreted as though they had been
written as 00123, 01230, and 12300, respectively. They would, therefore, be
assigned the values of 123, 1230, and 12,300. The point is that the user must
be very careful to enter this type of integer data right-justified in its
field. If he does not, it will be interpreted in the wrong way. Great care
must be taken, since justification errors are very difficult to see when an
input listing is being proofread.
The case for real data, which may include a decimal point, is slightly
less dangerous if the decimal point is always included. Using the above
example, the entries — bb!23., b!23.b, 123.bb, when entered in a six charac-
ter field would be interpreted as though they had been written as 00123.,
0123.0, and 123.00, respectively. These would all be assigned the same value.
In conclusion, all fields to contain numeric information will be
said to be integer or real in the following coding instructions. Information
being placed into integer fields may not be shown with a decimal point and
must be right-justified. Information being placed in real fields should
always be shown with an explicit decimal point and may be entered anywhere in
its field.
88
-------
The other type of information entered into the program is nonnumeric,
descriptive information. Fields containing this type of information will
be referred to as descriptive fields. Generally, information entered
into descriptive fields should be left-justified; however, the ramifications
of not following this convention are minor. It should be pointed out that
any character not included in the character set when used in a descriptive
field will be replaced by a blank in the program.
89
-------
6.2 The Equipment Inventory
From a logical standpoint, the first input which must be prepared
is the equipment inventory. This is by far the most complex input, but once
prepared, it is the least likely to change. The equipment inventory contains a
general mathematical description of each type of equipment of possible interest
in the simulation. This description is linked to the unit operations des-
cribed in the previous chapter. It should be pointed out that in the original
version of the program, the equipment inventory was hardwired into the
program. The advantage of this approach was that the user did not have to
concern himself with the details of the equipment specification.
From the standpoint of the current version of the program, the dis-
advantage of this approach is that the user has no control over the equipment
specification and, thus, cannot tune the program to particular applications
which do not follow the generalized behavior assigned to the equipment types
by Gottfried, Jacobsen, and Vaillant . The point is that there are two
very different, yet by no means incompatible, situations in which a program
like CPSM4 might be used.
In one situation the user is interested in simulating "the
performance of... configurations representative of actual preparation plants"
(Gottfried, Jacobsen, and Vaillant ). He is not simulating an actual
plant, but rather is examining a representative picture of some configuration
as it might impact on some type of coal. Such analysis is important and
valuable for the various design tasks which might precede the actual con-
struction of a plant or, perhaps more importantly, which might precede the
decision to even build a plant.
At the other extreme the user is not interested in a representative
configuration, rather he is interested In a very particular plant which might
already be in operation. If he could tune the equipment inventory description
to the point that the simulation results agreed closely with actual experience,
then he could effectively use the program to evaluate changes in the feed
characteristics of the coal and/or changes in the plant configuration or equip-
ment set points. This level of use is precluded by the approach taken in the
original version.
90
-------
Both levels of use, and any level in between, are possible in the
current version. The equipment inventory prepared for the user handbook
example, which is completely described in the following section, contains all
of the equipment types included in the original version. It is just these
types for which generalized descriptions have been prepared. Those users who
only wish to use the program in its representative mode may simply take that
input as given and need not study the following discussion which relates to
specifying the equipment inventory. Figure 1-6-2.1 shows the equipment types
for which general characterizations have been prepared.
91
-------
Code
41
51
52
1
2
3
4
5
6
7
11
12
13
14
15
16
17
18
19
21
22
23
24
Equipment type
stream blender
stream splitter
centrifuge
concentrating table
dense-medium vessel
dense-medium cyclone
hydrocyclone
single-stage Baum jig
two-stage Baum jig
froth flotation cell
rotary breaker
primary multiple roll crusher
primary gyratory/jaw crusher
primary single roll crusher
primary cage mill crusher
secondary multiple roll crusher
secondary gyratory/jaw crusher
secondary single roll crusher
secondary cage mill crusher
dry upper screen
dry lower screen
wet upper screen
wet lower screen
Unit operation
blending
splitting
splitting
washing
washing
washing
washing
washing
two-stage washing
froth flotation
rotary breaking
crushing
crushing
crushing
crushing
crushing
crushing
crushing
crushing
screening
screening
screening
screening
FIGURE 1-6-2.1. THE GENERALIZED EQUIPMENT INVENTORY
92
-------
6.3 Coding the Equipment Inventory
Figure 1-6-3.1 contains the field descriptions to be used in
coding the equipment inventory segment of the input deck to the program,
while Figure 1-6-3.2 contains a listing of the actual equipment inventory
segment used for the user handbook example. This equipment inventory
includes not only the actual equipment types used in the example plant con-
figuration, but also all other types for which generalized data is available.
On Figure 1-6-3.1 the fields are organized into eight general card types as
shown. This part discusses these card types, their organization into the
equipment inventory, and their content in detail.
Since the primary purpose of the equipment inventory segment of
the input deck is to give the user selective access to and control of the
unit operations contained within the program, this discussion will rely heavily
on the material presented in the previous chapter on the mathematics of the
unit operations. Unfortunately, some references to the material in the fol-
lowing chapter on interpreting the output of the program must also be made.
It is hoped that these do not cause too much difficulty.
6.3.1 Equipment Inventory Count Card
The first card in the equipment inventory segment of the input deck
to program CPSM4 is the equipment inventory count card. This card contains
a single integer field in columns 1 through 5. This field specifies the num-
ber of equipment types to be included in the inventory. In the case of the
user handbook example, this field contains the entry 23 which represents the
total number of equipment types for which generalized data have been prepared.
The equipment inventory count card for the user handbook example is shown as
the first card in Figure 1-6-3.2. Following the equipment inventory count
card in the inventory segment of the input deck, there are as many equipment
type subsegments as spacified in the inventory count field.
93
-------
I. Equipment Inventory Count Card
Field Type Description
1_5 integer number of equipment types
II. Equipment Type Definition Card
Field Type Description
1-5 integer identifier for equipment type
6-10 integer unit operation code for equipment type
code unit operation
1 blending
2 splitting
3 screening
4 washing
5 two-stage washing
6 froth flotation
7 rotary breaking
8 crushing
11-15 integer prebreakage control flag for equipment type
41-80 descriptive description of equipment type
III. Washing Special Information Card
Field Type Description
1-8 real offset for denominator in imperfection calculation
IV. Rotary Breaking Special Information Card
Field Type Description
1-8 real number of falls calculation constant
9-16 real hole size threshold value
17-24 real screening constant if hole size below threshold
25-32 real screening constant if hole size not below threshold
33-40 real height selection factor for breakage adjustment
FIGURE 1-6-3.1. FIELD DESCRIPTIONS FOR CODING EQUIPMENT INVENTORY
94
-------
V. Crushing Special Information Card
Field Type Description
1-8 real selection constant
9-16 real crushing range calculation constant
17-24 real screening constant
VI. Distribution Definition Card
Field Type Description
1-5 integer curve set type code
code meaning
1 1-dimensional vector
2 univariate distribution
3 size classification curves
4 c-generalized distribution curve
5 nongeneralized set of distribution curves
6-10 integer number of points per vector or distribution
11-15 integer number of size fractions or univariate distri-
butions or size distributions
VII. Miscellaneous Real Values Specification Card
Field Type Description
1-8
9-16
17-24
25-32 these fields are used for the entry of
33-40 real miscellaneous real values associated with
41-48 the specifications of the equipment distributions
49-56
57-64
65-72
73-80
VIII.- Miscellaneous Integer Value Specification Card
Field Type Description
1-5 integer This field is used for the entry of miscellaneous
integer values associated with prebreakage.
FIGURE 1-6-3.1, (Continued)
95
-------
IX. Number of Curves per size Fraction Card
Field Type Description
1-5
6-10
11-15. these fields specify the number of
16-20 integer actual distribution curves to be
specified per size fraction
76-80
FIGURE 1-6-3.1. (Continued)
96
-------
23
<»1 1
51 2
5221
6
1
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0.7261* 0.576'. 0.
21 3
13.
60.
18.
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18.
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1.0
100
1
1
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1 i*
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1
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25
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5
STREAM BLENDER
STREAM SPLITTER
CENTRIFUGE
0.0058 0.0029
0.271.2
DRY UPPER SCREEN
0.093 0
3.0 0
DRV LOWER
0.093 0
2.0 0
WET UPPER
0.093 0
3.5 3
HET LOWER
1
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375 0.
6 i*.
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5
0.093 0
2.3 0
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SCREEN
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6 0.
0161* 0.
7 0.
0161* 0.
7 a.
0116
5
0116
5
0116
55
0116
55
CONCENTRATING TABLE
7
2520
8691*
0186
9930
3000
85C9
0288
9970
3000
8279
0665
9970
1000
7951*
3573
9930
1950
7813
2953
991*0
3660
8122
2631*
9770
2370
7757
3623
9980
3390
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1.0532
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1.0387
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1.0626
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1.1252
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1.3981
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1.3987
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9720
3730
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9320
3260
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2190
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1.0769
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1.1093
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2.0560
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1.C332
1. 5566
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1.7532
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5000
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1.07 1.0
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C. 00 00
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2.0539
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. 0100
FIGURE 1-6-3.2. (Continued)
99
-------
. 7656
1. 3853
1. 0000
. <«000
6
1.0
4
100. 0000
. 8432
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5
20 7
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1.1248
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1.2864
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1.2158
.9850
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1.2129
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.8385
1.4921
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1.6250
.8538
1.1234
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1.2800
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1.3862
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1.3926
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.9015
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1. 1409
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1. 3318
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1.2501
.9700
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1.2734
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.8880
1.6171
.9750
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.8667
1.1814
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. 3800
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1.4003
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1.1989
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1.7421
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.8836
1.0340
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.9120
1.3454
.8690
.3830
.8993
1.1651
.9670
.3570
.9016
1.4118
.9450
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.9528
1.2958
.9520
.1420
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1.4745
.9690
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.9374
1.7421
.9480
.2670
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.8850
1.2297
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.3450
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1.5863
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1.8274
.0619
.2274
.9185
1.5547
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.2904
.3247
1.J444
.9635
1.940G
.9250
.2290
TWO-STAGE
.0930
.9137
1.0406
.6990
0.0000
.9225
1.0559
.8140
.0750
.9053
1.2739
.9550
.0340
.9156
1.5329
.9220
.0860
.8798
1. 3624
.9310
.1140
.8691
1.5372
.9370
.0890
.9635
1.9400
.9250
.2290
.0930
.8957
1.2845
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.9190
1.9003
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.1490
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2.3220
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.1188
.9560
1. 8144
^1354
.2583
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1. 3123
1.0156
2.1848
.8730
.1930
BAUM JIG
.0460
.9400
1.0415
.5000
0.0000
.9292
1.1131
.7500
.0350
.9637
1.4551
.6990
.0150
1.0397
1.6788
.6810
.0610
.8986
1.4414
.8990
.0880
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1.6129
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1.0156
2.1848
.8730
.1930
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. 9086
1.3898
. 1906
.2730
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2.1880
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1.0542
2.3232
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1.0342
2.0412
.2679
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.8798
1.3685
1.1497
2.6040
.7020
.1430
0.0000
.9729
1.0425
.2230
O.OOCO
.9530
1.1741
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0.0000
1.0070
1.7522
.5000
0.0000
1.0810
1.8377
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.0400
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1.5558
. 7330
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1.7318
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1.1497
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1.5347
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2.1891
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1.1610
2.3243
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1.1340
2.2680
.3680
.2036
.8946
1.4946
1.3020
2.6063
.5000
.1430
.9908
1.0340
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0.0000
.9730
1.1750
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0.0000
1.0523
1.7532
.2990
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1.1761
1.8388
.2750
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1.0400
1. 7763
.5000
.0280
1.0810
1.8982
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.0160
1.3020
2.6053
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.1430
.9709
1. 6840
.4707
.1980
1.0940
2.1902
.4573
.0680
1.1749
2.3255
.4258
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1.1884
2.2691
.3883
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1.6960
1. 3619
2.6066
. 4220
.1430
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1.0349
.0640
0.0000
.9787
1.1760
.2500
0.0000
1.0916
1. 7542
.1310
0.0000
1.1880
1.8399
.2550
.3400
1.1055
2.0800
.3660
0.0000
1.1264
2.0539
.3970
.0100
1. 3619
2.6066
. 4220
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2.0406
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1.1224
2.1913
. 4425
.0680
1.2028
2.3266
.4189
.1188
1.2100
2.5678
.3834
.1748
.9964
2.1200
FIGURE 1-6-3.2. (Continued)
100
-------
0.
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•
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•
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1. 5711
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FROTH FLOTATION
7
.3800
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ROTARY BREAKER
C.20 0
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FIGURE 1-6-3.2. (Continued)
101
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PRIMARY MULTIPLE ROLL CRUSHER
O.lQi.1 C.0522 0.0366 0.0260
0.22 O.li. Q.ii Q.09
PRIMARY GYRATORY/JAW CRUSHER
O.lQi.1 0.0522 0.0368 0.0260
0.20 0.19 0.17 0.12
PRIMARY SINGLE ROLL CRUSHER
O.lfli.1 C.0522 0.0368 0.0260
0.10 0.05 0.03 0.02
PRIMARY CAGE MILL CRUSHER
0.1041 0.0522 0.0368 0.0260
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SECONDARY MULTIPLE ROLL CRUSHER
0.101*1 0.0522 0.0368 0.0260
0.22 0.1
-------
1.0 0.96 0.79 C.<*5 0.20 0.10 0.05 0.03 0.02 0.0
0.0
18 8 SECONDARY CAGE MILL CRUSHER
0.85 1.7 2.0
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1.0 0..8308 0.5882 O.*»176 0.2065 O.lC'tl 0.0522 0.0368 0.0260 0.0131
0.0
1.0 G.8
-------
6.3.2 Equipment Type Definition Card
The first card in each equipment type subsegment of the inventory
segment of the input deck is the equipment type definition card. The purpose
of this card is to supply the basic definition of the equipment type being
described. This definition contains three distinct components: first, the
equipment type identifier; second, the unit operation used to simulate the
equipment type; third, a flag to control prebreakage in the unit; and fourth,
a description of the equipment type.
The equipment type identifier is used to refer to that equipment
type at other places in the input deck. In particular, the equipment type
of actual units within the plant configuration is indicated via this
identifier. The identifiers also appear in the two unit summary reports along
with a descriptor. This can be seen on pages 1 and 67 of the user handbook
example printout in Appendix A (pages 154 and 220).
The unit operation code of that unit operation being used to simu-
late the equipment type is, of course, crucial to relating the type to the
actual mathematical operations within the program. The actual codes used to
refer to the unit operations are defined in Figure 1-6-3.1. The organization
of the remainder of this part of the chapter reflects that fact.
The prebreakage control flag determines whether the feed to the unit
is to be broken prior to entering the unit. If the flag is set to zero, no
prebreakage is to occur; if the flag is set to one, prebreakage will take place
and information specifying the prebreakage precedes the equipment type special
information.
The descriptor of the equipment serves two very important functions.
Most importantly, it documents the input subsegment by labeling it. Such
labels are extremely important as an aid in finding the appropriate places in
an input deck when changes are needed. Secondly, this descriptor is used as
the unit descriptor within a plant configuration for units of that type when
no explicit unit descriptor is specified.
It should be observed that the equipment type identifiers and the
equipment type descriptors match exactly those which are hardwired into the
original version of the program. This convention was followed to achieve as
much downward compatibility as possible with the revised version.
104
-------
ji.3.3 Coding Splitting and Blending Equipment
Of all the equipment-type subsegments of the equipment segment of
the input deck, the simplest, by far, are those for splitting and blending
equipment. Both of these subsegments consist only of the single equipment-
type definition card. This is because neither operation requires any addi-
tional special information or empirical distributions. The second and third
cards of Figure 1-6-3.2 show the equipment type subsegments for a stream
splitter and stream blender, respectively.
6.3.4 Coding Washing Equipment
In addition to the equipment-type definition information the
washing equipment requires two other types of information: a special informa-
tion parameter specifying a constant for one of the unit performance measures;
and a set of empirical distributions - either c-generalized or nongeneralized -
used for computing the size fraction specific distribution curves for that
equipment type. There are five examples of washing equipment-type segments
of the input deck included in Figure 1-6-3.2. These correspond to the five
types of washing equipment for which c-generalized curves have been constructed
There are no examples of entering nongeneralized curves in this equipment
inventory.
Immediately following the washing equipment type definition card
within each equipment inventory subsegment, is the washing special information
card. This card contains a single real field entered in columns 1 through 8
which specifies the offset for the denominator in the calculation of imper-
fection, a unit performance measure. This calculation is discussed in the
next chapter. Suffice to say, at this point, that its value is one or zero.
For the dense-medium vessel and dense-medium cyclone, it is set to zero; while
for the remaining washing equipment types, it is set to one. These settings
are reflected in the listing in Figure 1-6-3.2.
105
-------
Following the washing special information card is that subsegment
which actually defines the empirical distribution to be used in computing the
distribution curve for the washing equipment type being defined. The first
card of any subsegment defining an empirical distribution is the distribution
definition card. This card is used to generally define the type and size of
the distribution. Its first field contains the distribution type code. The
possible codes which may be used in general are shown in Figure 1-6-3.1. In
so far as washing equipment types are concerned, only curve type 4,
c-generalized distribution curve, or curve type 5, nongeneralized set of
distribution curves, may be specified. The second field in the distribution
definition card specifies the number of empirical points used to define each
curve in the distribution, and the third field specifies the number of size
fractions.
Since both curve set types 4 and 5 are size fraction specific, the
next card, or cards, immediately following the distribution definition card
are used to define the size fraction classification scheme. The card type
used is the miscellaneous real values specification card. This card simply
contains ten real fields, each eight columns wide. The sequence of values
are entered successively in these fields. If more than ten values are being
entered, a second card is used. This continues until all values have been
entered.
All size fraction classification schemes being defined for the
program are entered in the same manner. This will be described in detail
here. Several later parts in this chapter will refer back to this description.
As mentioned earlier, the size of a particle of irregular shape, such as a
coal particle is definable in several ways. Throughout this discussion the
size of a particle is the width of the square aperture through which the
particle will just pass-. A size fraction is a closed-open sequence of two
decreasing values, say [S , S ), i.e., a particle is said to be of that
nidx Tiiiii
size fraction if it would pass through any square aperture whose width is
greater than or equal to S and would fail to pass through any square aper-
in 3.x
ture less than or equal to S in width.
mm
106
-------
A monotone decreasing sequence of n+1 values (S , ...,S ,S ) defines
a set of n size fractions ([S ,S .,),...[S. S. n ),..., [Sn ,S )). This
n n—l i, i-l l o
sequence is referred to as a size fraction classification scheme. All values
associated with a size fraction classification for input into the program are
expressed in decimal inches, and entered in order on the miscellaneous real
values specification card. If the size fraction classification scheme contains
n fractions, then n+1 values must be entered. In the special case where
values are being defined only for the composite and only for one size fraction,
the sequence (100.0, 0.0) should be entered.
If nongeneralized distribution curves are being entered, then the
next card, or cards, following the size fraction definition specify the number
of curves per size fraction to be entered. These are entered via the number
of curves per size fraction card. Obviously, one integer value is entered
for each size fraction. Let n be the number of curves for size fraction s
s
and N be the number of size fractions. The total number of curves N is
s c
clearly computed as shown in (1)
N
s
N = I n (1)
c s
s-1
Still, only if nongeneralized distribution curves are being entered,
the next card, or cards, following the number of curves per size fraction card
specify the specific gravity of separation for each of the distribution
curves to be entered. A miscellaneous real values card, or cards, is used
to enter this information. The order begins with that curve which has the
lowest specific gravity of separation for the largest size fraction, followed
by the next lowest, and so on until all have been exhausted for the largest
fraction. Then the values for the next largest fraction are entered, and so
on until all have been specified.
107
-------
Immediately following the size definition card, if c-generalized
curves are being entered, or after the specific gravity of separation defini-
tion if nongeneralized curves are being entered, come the cards defining the
actual curve points. For each curve first the independent, x-value, points
are entered on a miscellaneous values specification card, or sequence
thereof. Then the dependent, or y-value, points are entered in the same-
manner. For generalized curves they are ordered from largest size fraction
to smallest. For nongeneralized curves, they are ordered as specified in the
previous paragraph.
Clearly, the preceding discussion is quite complicated. The reader
is encouraged to select one of the washing equipment types and to examine
its input in detail. In particular, compare the values being entered to the
table of values given for that equipment type in the previous chapter.
6.3.5 Coding Two-Stage Washing Equipment
The input subsegment for the two-stage washing equipment is almost
identical to that for the washing equipment which was described in the previ-
ous subpart. The only difference is that two distribution curve specifications
must be entered; therefore, little more will be said about this input
subsegment. The only example input for a two-stage washing equipment type in
Figure 1-6-3.2 is that for the two-stage baum jig.
The unit performance measures computed for two-stage washing equip-
ment are largely the same as they are for washing; therefore, the two-stage
washing type definition card is followed by the washing special information
card. The appropriate value for the imperfection offset of the two-stage
baum jig is one.
Each distribution curve subsegment entered for the two-stage
washer is identical in structure to the single curve'subsegment described for
the washer. The two definitions are completely independent of each other.
They need not even be of the same type - c-generalized or nongeneralized.
The curves defining the ratio to clean are entered first, followed directly
by the curves defining the ratio to middling.
108
-------
6.3.6 Coding Froth Flotation Equipment
Coding of the froth flotation equipment type requires two types of
information in addition to the equipment type definition. The first is the
same value for the imperfection unit performance measure as was entered for
the washing and two-stage washing types. It is entered in the same manner
as before on a washing special information card immediately following the
froth flotation type definition card. The only example of a froth flotation
equipment type is the froth flotation cell. The imperfection offset for this
example is one.
The second type of information which must be entered consists of
that set of generalized curves from which the froth flotation unit operation
should attempt to extract an actual distribution curve giving the desired
yield and percent ash. These curves are simply entered as a set of univariate
distribution curves.
The distribution definition card, immediately following the washing
special information card within the froth flotation equipment type subsegment
of the input deck, must then specify a curve set type code of 2. The second
field on this card defines the number of points per curve, and the third
defines the number of curves. Following this card are the actual curve
definitions entered via the miscellaneous real value cards in the same manner
as the actual curves were entered for washing - the x-values followed by the
y-values of the first curve, then the second curve, and so on.
6.3.7 Coding Screening Equipment
For the screening equipment only an empirical distribution is needed
in addition to the screening definition card. As with washing there are two
types of empirical distributions which may be defined. First, a simple distri-
bution over mesh size which specifies the adjustment factor to be used in the
general screening equation; and second, a set of explicit size classification
curves, where the particular curve used is a function of mesh size.
109
-------
In the case where an adjustment factor distribution is being defined
the card immediately following the screening type definition card is a distri-
bution definition card with a curve set type code of 2, which specifies that
a univariate distribution is being defined. The second field on the distri-
bution definition card specifies the number of points used to define the dis-
tribution, and the third field would contain a constant 1, since only one
distribution is needed. This card is followed by a group of miscellaneous
values cards (possibly only one) defining the x-points, and then a group
defining the y-points. All of the screens in the user handbook example inven-
tory are defined in this manner. The reader can compare the values entered
in Figure 1-6-3.2 to those presented in the tables under the screening unit
operation (Part 4.3).
In the other case the screening equipment type can be defined via
an explicit set of size classification curves. There are no illustrations of
this type of definition in the example. This type of definition is coded
as follows. Immediately following the screening type definition card is a
distribution definition card which specifies a curve set type code of 3.
This code indicates that a set of size classification curves are being defined.
The second field on the distribution definition card specifies the number of
points in each size classification curve, which in this case is also the num-
ber of size fractions into which the curves classify the flows. The third
field on the card defines the number of curves. Following the distribution
definition card is a miscelleneous values card defining the size fraction
classification scheme as described in the part on washing. Then the card
which specifies the mesh size for each classification curve is entered.
This card is also a miscellaneous values card. The mesh sizes should be
specified in monotone increasing order. Finally the miscellaneous values
cards defining the size classification curves in the same form as all other
curves are placed in the input subsegment.
6.3.8 Coding Rotary Breaking Equipment
The rotary breaking equipment type has associated with it a series
of special information entries and two 1-dimensional vectors. An example of
110
-------
a rotary breaking equipment type is included in the equipment inventory seg-
ment listing in Figure 1-6-3.2. The reader is referred back to the part on
the rotary breaking unit operation for a detailed discussion of the various
constants and vectors entered for equipment types using the rotary breaking
unit operation.
The first card after the rotary breaking type definition card is
the rotary breaking s'pecial information card. The fields on this card are
adequately described in Figure 1-6-3.1 and the values for these fields are
shown in Figure 1-6-3.2. There are two distributions needed for rotary
breaking equipment: the first defines the selection vector for the coal
stream, and the second defines that vector for the rock stream. Each vector
is introduced via a distribution definition card containing a 1 in the curve
set type code column, the number of points in the distribution in the second
field, and a constant 1 in the third field. Each distribution definition
card is then followed by a single group of miscellaneous values cards (or
possibly a single card) which specify the selection vector in order by fall
number.
6.3.9 Coding Crushing Equipment
There are eight types of crushing equipment defined in the equip-
ment inventory for the user handbook example as shown in Figure 1-6-3.2. Each
type requires three special information A-alue- and one empirical distribution
defining the breakage function to be used for that material larger than the
crushing range maximum. Given the description in Figure 1-6-3.1 and 1-6-3.2
and the previous discussion, the coding procedure is straightforward.
6.3.10 Coding Prebreakage Information
Four types of information are required for prebreakage. The first
two cards are miscellaneous integer value cards, the first containing the
number of size fractions defining the prebreakage, the second containing the
power of the breakage matrix to be used. Next comes a miscellaneous real values
card supplying the --ize fractions defining the prebreakage. Finally comes
another miscellaneous real values card specifying the selection factor for pre-
breakage .
Ill
-------
6.4 Defining the Configuration
Once che equipment inventory has been specified, the configuration
of units of those equipment types may be defined. The coding of this con-
figuration is trivial if the user has a clear representation of it when he
is doing the-coding. This discussion introduces a box flow diagram, -
which constitutes such a representation. The use of this notation has
three major advantages. First, it simplifies the task of defining the units
and flows in the desired configuration to the program. Second, since coal
preparation engineers and management personnel are accustomed to evaluating
circuits in terms of drawn flowsheets, this type of notation is already
familiar to the potential users of the program. Third, if all users use
the same notation, then the communication of configurations between users
is greatly simplified.
The block diagram notation contains two types of symbols - the unit
block and the flow arrow. The unit block is structured as shown below. The
symbol seq represents the processing sequence number of the unit. CPSM4
simulates the units in the order defined by this sequence number. Obviously
the unit which accepts the feed to the plant must be assigned the sequence
number of one. In addition, any unit which inputs a flow produced by
another unit must have a sequence number higher than that unit. The symbol
id represents the identifying code of the equipment type to which the unit
belongs. This identifier must be present in the equipment inventory. The
symbols Dl, D2, and D3 represent the values of the decision variables to be
included. The number and type of these is determined by the unit operation
associated with the equipment type to which the unit belongs. Figure 1-6-4.1
summarizes the decision variables by unit operation.
seq
id
Dl, D2, D3
112
-------
Unit operation
Blending
Splitting
Screening
Washing
Two-stage washing
Froth flotation
Rotary breaking
Crushing
Decision variable
Dl - percent moisture of output flow
Dl - percent to upper flow
D2 - percent moisture of upper flow
Dl - mesh size in inches
D2 - percent moisture of upper flow
Dl - specific gravity of separation
D2 - percent moisture of clean flow
Dl - specific gravity of separation
D2 - percent moisture of clean flow
D3 - percent moisture of middling flow
Dl - percent moisture of clean flow
Dl - length of drum in feet
D2 - diameter of drum in feet
D3 - size of opening in inches
Dl - crusher setting in inches
FIGURE 1-6-4.1. DECISION VARIABLES
113
-------
The flow arrow is structured as shown below.
The type code is intended to indicate the type of output represented by the
flow. Figure 1-6-4.2 shows the types of codes which may be used to
characterize flows.
Associated with each unit operation type are a certain set
of flowstream types which must be included. These are shown in Figure 1-6-4.3,
The flow sequence number is used to identify the flows. It should be
assigned as follows. The feed stream is assigned a sequence number of one.
The flows coming out of the first unit are numbered in order by their codes,
as shown in Figure 1-6-4.3, and so on. Figure 1-6-4.4 shows the configura-
tion for the user handbook example. Note that the double deck screen is
represented via a set of units and flows.
Type Description
C Clean coal stream
M Middlings stream
R Refuse stream
U Screen or splitter overflow (upper) stream
L Screen or splitter underflow (lower) stream
blank Any other type stream
FIGURE 1-6-4.2. FLOWSTREAM TYPE CODES
114
-------
Unit operation
Blending
Splitting
Screening
Washing
Two-stage washing
Froth fl-otation
Rotary breaking
Crushing
Code
U
L
U
L
C
R
C
R
M
C
R
C
R
Description
Any code may be used
The output flow receiving the specified percent
The output flow receiving the remainder
The upper (overflow) flow
The lower (underflow) flow
The clean output flow
The refuse output flow
The clean output flow
The refuse output flow
The middling output flow
The clean output flow
The refuse output flow
The coal output flow
The refuse output flow
Any code may be used
FIGURE 1-6-4.3. UNIT OPERATION FLOW TYPE ASSOCIATION
115
-------
Rotary Breaker
Feed
T
9 ] C4I
t/17\
\0s
T
a 1 cis
01=0.275
Secondary
Multiple
iT/Wel Single Roll
Deck Screen Crusher
Clean
FIGURE 1-6-4.4. CONFIGURATION OF USER HANDBOOK EXAMPLE
116
-------
6.5 Coding the Configuration
Once the configuration has been defined, coding it is trivial.
Figure 1-6-5.1 contains the field descriptions for coding the configuration.
Figure 1-6-5.2 shows the listing of the input describing the configuration
for the user handbook example. The only limitation on configurations is
that no configuration may contain more than 60 units or 100 flows. The unit
cards must be arranged in order by their sequence numbers. This also holds
for the flow cards.
117
-------
I Configuration Key Card
Field Type Description
1-4 descriptive data base configuration key
II Configuration Control Card
Field Type Description
1-5 integer number of units in configuration
6-10 integer number of flows in configuration.
Ill Unit Definition Card
Field Type Description
1-5 integer equipment type identification code
11-20 real value of first decision variable, if relevant
21-30 real value of second decision variable, if relevant
31-40 real value of third decision variable, if relevant
41-80 descriptive description of unit.
IV Flow Definition Card
Field Type Description
1-5 integer unit number of origin (0 if origin external)
6-10 integer unit number of destination (0 if destination external)
12-12 descriptive flow type code.
FIGURE 1-6-5.1. FIELD DESCRIPTIONS FOR CONFIGURATION
113
-------
EX1C CONFIGURATION KEY
19 29
11 20.0 12.0 6.0 ROTARY BREAKER
<»1 67.5 BLENDER (ACOS WATER'
23 1.50 15.0 WET UPPER SCREEN
2U 0.5 15.0 MET LOWER SCREEN
<»1 STREAM BLENDER
6 1.62 TWO-STAGE EAUM JIG
«*1 STREAM BLENDER
16 0.275 SECONDARY MULTIPLE ROLL CRUSHER
«»1 STREAM BLENDER
23 0.0232 15.0 WET SINGLE DECK SCREEN
1 1.5d CONCENTRATING TABLE
kl STREAM BLEN3ER
7 20.0 FROTH FLOTATION CELL
«ti STREAM BLENCER
52 99.0 k.O CENTRIFUGE
<*l STREAM BLENDER
<»1 STREAM BLENDER
52 99.0 3.0 CENTRIFUGE
0 1
1 2 C
2 3
1 7 R
3 5 U
3 <» L
«f 5 U
<» 9 L
5 6 U
6 17 C
6 8 M
6 7 R
7 12 R
a 9 M
9 10 M
10 11 U
10 13 L
11 16 C
11 12 R
12 l
-------
6.6 Coding the Feed
Figure 1-6-6.1 shows the field definitions to be used in coding the
feed to the plant; while Figure 1-6-6.2 contains the listing of the input for
the user handbook example. The structure of this subsegment is straightforward,
The first card is a feed control card. This is followed by a sufficient number
of size fraction cards to define the feed size distribution. Then come the
specific gravity fraction cards which define the specific gravity fractions.
The characteristic sequence card comes next, specifying the sequence numbers
of the characteristics ash, total sulfur, and Btu/lb. Following this, come
as many characteristic definition cards as there are characteristics, including
the flowrate or weight. These cards define the row and column headings of the
characteristics for the output tables. Following this come up to thirty input
feed subsegments.
The first card in each input feed subsegment is the feed key card
specifying the key for the feed on the data base. If the key is blank, the
last input feed subsegment has been processed. Next comes the input feed
control card followed by the size fraction weight card specifying the relative
weights of each size fraction in the feed. If the Btu control code is zero,
the Btu values for the various specific gravity fractions are entered next.
Following this come the individual feed fraction characteristics on flow value
cards. The ordering of the characteristics is that given by the characteristic
definition cards with the proviso that the flowrate or weight must be the first
characteristic. If the missing size fraction code is 1, then the composite
characteristics of the smallest size fraction are entered next. If the Btu
control code is 2 there follow three cards specifying the number of points
given for interpolation, and the ash and Btu values for interpolation. This
completes the cards in an input feed subsegment.
120
-------
I Feed Control Card
Field Type Description
1-5 integer number of size fractions
6-10 integer number of specific gravity fractions
11-15 integer number of characteristics.
II Size Fraction Card
Field Type Description
1-8
9-16
17-24
25-32
33-40 real these fields are used for the entry of the size fractions
41-48
49-56
57-64
65-72
73-80
III Specific Gravity Fraction Card
Field Type Description
1-8
9-16
17-24
25-32
33-40 real these fields are used for the entry of the specific
gravity fractions
41-48
49-56
57-64
65-72
73-80
FIGURE 1-6-6.1. FIELD DESCRIPTIONS FOR SPECIFYING FEED
121
-------
IV Characteristic Sequence Card
Field Type Description
1-5 integer sequence numbers of ash in characteristic list
6-10 integer sequence numbers of total sulfur in characteristic list
11-15 integer sequence numbers of Btu/lb in characteristic list
V Characteristic Definition Card
Field
1-5
7-36
38-44
46-52
Type
descriptive
descriptive
descriptive
descriptive
VI Feed Key Card
Field Type
1-4 descriptive
Description
characteristic code
row descriptor for characteristic
first line of column heading for characteristic
second line of column heading for characteristic
Description
data base feed key
VII Input Feed Control Card
Field Type Description
7-9 integer missing size fraction code
code meaning
0 all size fractions are included
1 smallest size fraction is to be estimated
13-15 integer Btu control code
code meaning
0 Btu values are specified by specific gravity
fraction only
1 Btu values are included for all size and
specific gravity fractions
2 Btu values are interpolated
VIII Size Fraction Weights Card
Field Type Description
1-6
7-12
FIGURE 1-6-6.1. (Continued)
122
-------
VIII (continued)
Field Type Description
13-18
19-24
25-30
31-36
37-42 real these fields are used for the relative weights of
each size fraction
43-48
49-54
55-60
61-66
67-72
73-80
IX Btu Values Card
Field Type Description
1-10
11-20
21-30
31-40
41-50 real these fields are used for the entry of the Btu's
per specific gravity increment if the Btu's are
being specified by specific gravity fraction only
51-60
61-70
71-80
X Flow Values Card
Field Type Description
1-10 real direct percent of weight
11-20
21-30
FIGURE 1-6-6.1.(continued)
123
-------
X (continued)
Field Type Description
31-40
41-50
51-60 real these fields are used for the direct percent,of
each characteristic (for Btu's it is the Btu/lb).
61-70
71-80
XI Smallest Size Fraction Characteristic Value
Field Type Description
1-10
11-20
21-30
31-40 real these fields are used for the entry of the overall
characteristic values for the smallest size fraction,
if the smallest size fraction values are to be
estimated.
41-50
51-60
61-70
71-80
XII Number of Points for Btu Interpolation Card
Field Type Description
1-5 integer if the Btu's are to be interpolated using the percent
ash of the coal, this card contains the number of
points used in defining the Btu variation with ash.
FIGURE 1-6.6.1. (Continued)
124
-------
XIII Ash Values for Btu Interpolation Card
Field Type Description
1-10
11-20
21-30
31-40 real if the Btu values are to be interpolated, these
fields contain the values of the independent
variable (ash).
41-50
51-60
61-70
71-80
XIV Btu Values for Btu Interpolation Card
Field Type Description
1-10
21-30
31-40
41-50 real if the Btu values are to be interpolated, these
fields contain the values of the dependent
variable (Btu's) for the interpolation.
51-60
61-70
71-80
FIGURE 1-6-6.1.(continued)
125
-------
8
18.3
1
2
WT
ASH
PS
TS
BTJ
EXIF
7.
15355
19. T
11.0
2.1
11.3
2.1
1.9
.a
51.1
16.7
1<«.3
5.3
5.3
<«.!
2.1
1.2
50.9
21.30
11.8
2.2
12.10
1.9
1.7
.70
<»7.9
22.0
19.9
6.9
7.5
U.5
2.2
1.6
35. 2C
33. k
23.15
7.5
6.9
3.2
l.S
1.5
22.i»
<47.8
19. k
5.9
8
12.0
.26 1.
i»
5
6.0 2. u
30 1.35 1
5
HEIGHT OF FLOW
ASH, PERCENT
PYRITIC
SULFUR, PERCENT
TOTAL SULFUR, PERCENT
BTU/L9,
0
2 23.6
1<»90
2.8
14.1.
7. 8
15.1.
25.0
31.5
<»1.0
8I..6
2.9
if .7
9.4
16.7
26.7
35.1
U5.7
82.9
2.8
<».<•
7. 8
15.3
21..9
31.5
i»1.0
9I..6
2.«
2£. J2
.61.
.69
.92
1.17
1.86
3.b3
ii.O1.
21.89
.69
.99
1.50
FIGURE 1-6-6.2. INPUT LISTING FOR FEED
126
-------
4.9
2.3
1. 4
1.1
16.9
59.0
12.5
8.5
4.2
2.0
1.0
.6
12.2
36.4
24.0
15.6
5.6
2.3
1r
. u
.5
14.7
15.4
24.4
33.3
41.7
62.8
1.8
6.4
8.3
15.5
22.8
23.4
34.3
67.7
1.2
2.7
4.2
11.0
17.6
24.1
32.2
67.3
1.50
2.20
3.45
6.28
21.02
.16
.73
1.02
2.05
3.27
4.51
6.44
20.43
.10
.28
.41
1.14
2.39
4.09
7.44
25.60
2.02
2.67
4.0*i
6.73
21.72
.73
1.24
1.49
2.63
3.73
5.17
7.22
21.41
.64
.84
1.01
1.66
2.98
4.32
8.06
26.50
BLANK KEY INDICATES NC MORE FEEDS
FIGURE 1-6-6.2. (Continued)
127
-------
6.7 Configuration and Feed Selection
The configuration and feed selection segment of the input data deck
is used to select the desired configuration and input feeds from the,data base.
This segment is required even if the equipment inventory, configuration, and
feed descriptions are supplied in coded card-image form in the input data deck.
The first card in this segment is the data base key for the configuration to
be used in this run. Next is the code for the number of feeds to be combined
into the input feed to the plant configuration. If the number of feeds code
is positive there follow the indicated number of pairs of cards specifying
the data base key for each feed required and the weight or flow rate of that
feed. Finally there is another card specifying the code for the number of
feeds. If this code is zero, execution of the program stops after the first
run. If the code equals -1, a second run of the program is desired and another
complete input data deck should follow. If the code is positive then a new
run is to be made using the same configuration as before but a different input
feed. In this case, a second set of feed keys and weights should follow.
Figure 1-6-7.1 shows the field definitions to be used in coding this segment
of the input data. Figure 1-6-7.2 contains the listing of the input for the
user handbook example.
128
-------
I Configuration Key Card
Field
Type
Description
1-4 descriptive data base key for configuration
II Feed Control Card
Field Type Description
1-5 integer number of feeds code
code meaning
-1 a new run is to be started; read in
a new run control card and configuration
0 stop program execution
+n number of feeds
III Feed Kev Card
Field
Tvpe
Description
1-4 descriptive data base key for feed
IV Feed Flow Rate Card
Field Type Description
1-10 real flow rate or weight of current feed
FIGURE 1-6-7.1. FIELD DESCRIPTIONS FOR
CONFIGURATION AND FEED SELECTION
129
-------
exic
i
EXIF
500.0
0
FIGURE 1-6-7.2. INPUT LISTING FOR CONFIGURATION AND
FEED SELECTION
130
-------
6.8 The Run Control
The first card in every input deck is the run control card. Figure
1-6-8.1 shows the field specifications for this card. For the user handbook
example, the first field contained
USER HANDBOOK EXAMPLE
while the other fields contained 0, 0, and 2, respectively,
Field
Type
1-65 descriptive
66-70
integer
71-75 integer
76-80 integer
Description
description of run to appear on heading of each output
page
input control code
code meaning
0 the configuration and feed data are to be read
from cards and saved on data base
1 the configuration and feed data are to be read
from data base
cost component control card
code meaning
0 do not execute the cost component
1 execute the ccst component
output control code
code meaning
-1 do not execute the simulation component
0 print only unit and flow input and summary
reports
1 print above reports plus all unit performance
reports and flows which are external to plant
2 print all reports
FIGURE 1-6-8.1. FIELD SPECIFICATION FOR RUN CONTROL
131
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6.9 The Cost Component
Given the discussion in Section 5, the preparation of the input for
the cost component is straightforward. There are five input formats used.
Figure 1-6-9.1 presents each of these in detail, while Figure 1-6-9.2 shows
the input deck for the User Handbook Cost Example. Other than these two
figures no additional discussion seems necessary.
132
-------
I. Main Cost Computation Control Card
II.
Field
1-10
11
12
13
14-23
24-28
29-33
34-36
37-40
41-60
61-80
integer
integer
real
integer
integer
integer
integer
descriptive
descriptive
Description
Production constant
Production specification type code
Code meaning:
0 Production constant specifies annual
production of project
1 Production constant specifies annual
feed to project
Code defining output flows which are to be
considered to be producing salable output
Code meaning:
0 All output flows are salable
1 Only C output flows are salable
2 C and M output flows are salable
3 C, M, and R output flows are salable
Code defining which characteristic of the
coal is to be considered as the salable quantity
Code meaning:
0 Coal
1 Heat content
2 Ash content
3 Pyritic sulfur content
4 Total sulfur content
Btu/lb to heat unit conversion factor
Length of construction period
Length of operational period
Number of table functions
Number of cost scenarios
Units used to define costs
Units used to define production
Table function definition card
Field Type
Description
1-5 integer Table function identifier
6-10 integer Table function interpolation type code
Code meaning:
1 Use linear interpolation
2 Use 4-point Lagrangian interpolation
11-15 integer Number of points defining function
FIGURE 1-6-9.1. FIELD DESCRIPTIONS FOR CODING
COST COMPONENT
133
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III. Table function values card
Field Type
1-10
11-20
21-30
31-40 real
41-50
51-60
61-70
71-80
IV. Cost element definition
1-3
4
5
integer
integer
integer
6-8
9-11
12
integer
integer
integer
13-15
16
integer
integer
Description
Enter table function values
Cost element identifier
Level of detail code
Element type code
Code meaning:
0 Temporary value needed for computation
1 Annual production value
2 Depreciable capital investment
3 Nondepreciable capital investment
4 Operating expense
5 Depreciation
6 Other tax allowance
Initial time value in CFD into which element
value is to be added. If blank use default.
Final time value in CFD into which element value
is to be added. If blank use default.
Cost calculation argument type code
Code meaning:
0 Argument is first constant
1 Argument is value of some other cost
2 Argument is amount of material in flow
3 Argument is Btu's in coal
4 Argument is ash in coal
5 Argument is pyritic sulfur in flow
6 Argument is total sulfur in flow
Number of flowstream or identifier of cost
element to which argument relates.
Cost calculation type code
Code meaning:
0 Cost equals argument
1 Cost equals argument multiplied times
second constant
2 Cost equals argument raised to power
of second constant
3 Cost is value of table function
FIGURE 1-6-9.1. (Continued)
134
-------
IV. Cost element definition (continued)
Field Type
Description
17-19 integer Table function identifier
21-30 real First constant
31-40 . real Second constant
41-80 descriptive Description of cost element
V. Cost scenario control card
1
4-5
6-10
21-25
31-80
integer Type of profitability measure to be used
Code meaning:
0 Discounted cash flow
integer Depreciation type to be used
Code meaning:
0 Depreciation handled by cost elements
1 Straight line
integer Production assumption code
Code meaning:
0 Assume constant annual production
integer Number of cost elements to be changed
real Rate of profit desired (ratio)
real Income tax rate
descriptive Scenario description
FIGURE 1-6-9.1. (Continued)
135
-------
1560000. C
2120
13
33
1.3
203
53
?3
1<»3
153
163
103
93
133
3
12
222
232
3
3
3
21.2
3
3
3
3
3
3
2
3
3
3
1".
512
522
2
2
2
2
2
•>
2
2
-1
010 .09
110
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
2
2
1
1
2
2
2
2
2
2
1.0
11
M
61
51
71
121
201
221
2<*1
161
1<*1
191
11
211
1
1
1
1
1
1
1
1
1
221
231
2«.l
11
11
511
521
11
11
11
11
11
11
0.09
1
17500.0
176000.0
23000. 0
18000.0
12100.0
2i»00.0
1300.0
12000.0
23200.0
28200.0
16000. C
10000.0
75000.0
303000.0
520.0
20000. C
300. 0
350000.0
t<80. 0
50000.0
150000.0
500000.0
6861.0. U
(472680.0
920»16 FT SINGLE DECK SCALPING SCREEN
EISHT CELL BAUM TYPE JIG
6»16 FT DOUBLE DECK DEWATERING SCREENS
5*10 FT DOUBLE DECK REFUSE SCREEN
CRUSHER
CLASSIFYING CYCLONE 20 INCH DIAM NIHARO
HVOROCYCLONE 1«* INCH DIAM RUBBER LINED
3*13 FT SINGLE DECK DESLIMING SCREEN
CENTRIFUGAL DRYER
CENTRIFUGAL DRYERS
6*16 FT SINGLE DECK OESLIMING SCREEN
SU4P
PUMPS
TOTAL CAPITAL REQUIREMENT
TOTAL COST OF PREPARATION PLANT
RAH COAL STORAGE AND HANDLING
RAM COAL STORAGE AREA...20000 TON CAPAC.
RAH COAL BELT TO PLANT. ,.«*2 INCH HIDE
TRAMP IRON MAGNET
OTHER FACILITIES AND EQUIPMENT
CLEAN COAL BELT....36 INCH HLOE
CLEAN COAL STORAGE AREA...40000 TON
REFUSE BELT 36 INCH HIDE
REFUSE BIN
RAH COAL AND REFUSE HANDLING EQUIPMENT
UNIT-TRAIN LOADING FACILITY
CONTINGENCY
PREPARATION PLANT CONTINGENCY
RAH COAL STORAGE CONTINGENCY
OTHER FACILITIES CONTINGENCY
OPERATING AND MAINTENANCE COST
LABOR - SUPERVISORY (NON-UNION*
LABOR - OPERATING * MAINTENANCE (UNION)
FRINGE BENEFITS - NON-UNION
FRINGE BENEFITS - UNION
OTHER OVERHEAD
OPERATING SUPPLIES
OPERATING MAINTENANCE
MAJOR MAINTENANCE
ELECTRICITY
SUBCONTRACT SERVICES
FIGURE 1-6-9.2. INPUT DECK FOR USER HANDBOOK COST EXAMPLE
136
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7.0 INTERPRETING THE OUTPUT
The output of program CPSM4 includes eight types of reports:
(1) The units input report
(2) The flows input report
(3) The specific gravity analysis of flowstream report
(4) The performance characteristics of a unit report
(5) The summary data for units report
(6) The summary data for flows report
(7) The project cash flow description
(8) The discounted cash flow analysis.
Reports 7 and 8 were discussed in detail in Section 5. This chapter describes
reports 1 through 6.
The report formats themselves are largely as they were in the
original version. They were designed to be as self-explanatory as possible
and to follow normal conventions for reporting the type of information being
shown.
A user-supplied descriptor and a sequential page number appears at
the upper right-hand corner of each page of output. This convention was added
in the present version to simplify identifying the output.
137
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7.1 The Units Input Report
The first table normally printed by the program is the units
input report. The purpose of this report is to echo back to the user the
units specification as interpreted by the program. This report is issued
prior to the running of the actual simulation. It contains no calculations.
It is needed to aid the user in making certain that he has correctly specified
his units and configuration.
138
-------
7.2 The Flows Input Report
The second table normally printed by the program is the flows
input report. The purpose of this report is to echo back to the user the
flows specification as interpreted by the program. This report is issued
prior to the running of the actual simulation. It contains no calculations,
It is needed to aid the user in making certain that he has correctly speci-
fied his flows and configuration.
139
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7.3 The Flowstream Specific Gravity Analysis Report
A flowstream specific gravity analysis report can be issued for
every flowstream in the configuration in the following order:
(1) The input streams being blended to form the feed to the
configuration
(2) The feed to the configuration
(3) The output flows from each unit immediately following
the performance characteristics report for that unit.
As discussed in the previous chapter, the user has the option to control
which of these should be printed.
Chapter 3 of this section discussed how flows are represented in
the program and how those representations related to a report similar to the
specific gravity analysis report. That discussion will not be repeated here.
The size and relative weight are shown for each size fraction. The
convention for describing sizes is that all units are in inches, unless they
are explicitly suffixed with the letter M. In this case they are mesh. The
relative weight of the individual size fractions is expressed in terms of their
precent of the flow; for the composite, the actual weight or rate of flow is
given.
140
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7.4 The Unit Performance Characteristics Report
A unit performance characteristics report is issued for every unit
in the configuration immediately after the performance of that unit has been
simulated. Each report consists of two parts. The first part includes a
general comparison of characteristics of the input flows versus the output
flows. Each performance report contains this part. The second part relates
to measuring the detailed aspects of the performance. This part varies by the
unit operation type. Not every unit operation has such a second part associated
with it.
The actual values reported are clearly labeled and all values are
calculated in accordance with the normal conventions followed by the Bureau
of Mines. Nonetheless, this discussion provides a detailed description of the
calculations of the measures reported. This discussion not only serves as an
explicit documentation of the values reported but also provides an excellent
medium to review and consolidate the mathematical presentations given in
Chapters 3 and 4 of this section. Frequent reference will also be made to
the various printout tables for the user handbook example described in Chapter
2 of this section and included in Appendix A.
Many of the definitions given here and some of the discussion,
especially for the washers, are taken from Geer and Yancey . The reader
is referred to that article for additional information.
The first subpart of this discussion contains a description of the
general flow characterizations which appear on every unit performance summary
report. The remaining subparts describe the unit operation specific measures.
141
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7.4.1 The General Characterization
The first set of values given in each summary of performance
characteristics report is as follows for each input flow to the unit and
each output flow from the unit:
(1) Screen analysis, percent
(2) The percentage of the flow that belongs to each user-supplied
characteristic. For the heat content, Btu per pound
moisture free is used instead of the percentage
These values are given for each size fraction and for the composite. Their
calculation is straightforward, 'as shown in (1) below.
C = ( T. F /E F, \ x 100.0
t,s \g t,s,g g l,s,gj
(1)
C = / E F / E F, \ x 100.0
t,c ^s,g t,s,g s,g l,s,
Here C is the percentage by weight of material that is in size fraction s
t , s
and is of characteristic t. Size fraction c refers to the composite material
Note that for the screen analysis,
Cn = E F. /E F1 x 100.0 (2)
l,s g l,s,g g l,s,g
= 100.0
Relating the summary values shown for the flows to the information
shown in the specific gravity analysis reports, note that the screen analysis
values for a given size fraction agrees with the percent of flow value given
for that size fraction in the specific gravity analysis of the appropriate
flow stream. Also, the characteristic values agree with the corresponding
culumative percent values on the 100.0 percent row.
142
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7.4.2 Screening Measures
In addition to the general flowstream characterizations, the screening
performance measures include four additional quantities for each size fraction
and for the composite. They are:
(1) Weight ratio, underflow to feed, percent
(2) Btu ratio, underflow to feed, percent
(3) Undersize material in overflow stream, percent
(4) Overflow material in underflow stream, percent
To illustrate the calculations, reference is made to user handbook page 33 (p. 186)
which contains the summary of performance characteristics for unit number 10 -
a wet single deck screen with a 28 mesh opening.
The weight ratio, underflow (lower) to feed percent is simply as
shown in (3) .
100 x E FT ., /E FT ., = 100 x I (1-d ) FT . /E FT
g L,l,s,g g I,l,s,g g s I,l,s,g g I,l,s,g
(3)
= (1-d ) x 100
s
For the 100M by 325M size fraction this would be as shown in (4).
(17.4 x 0.581)7(187.1 x 0.111) x 100 = 48.7 (4)
This value differs slightly from the reported value of 48.9 only because of
round-off errors.
The Btu ratio, underflow to feed percent is as shown in (5) for the
individual size fractions. Note that L^ indicates the lower output flow which
is the underflow.
100 x E FT , /£ F_ , = 100 x! E (1-d ) F /E F
g L,b,s,g'g I,b,s,g g s I,b,s,g g I,b,s,g
= (1-d ) x 100 (5)
s
Here characteristic b is used to refer to the Btu per pound.
143
-------
The reader is reminded that the screening unit operation classification curve
values, d , are specific gravity independent and that the screen unit operation
s
exhibits characteristic invariance. As a result, the values for Btu ratio,
underflow to feed percent are always identical to the value of weight ratio,
percent underflow to feed for the individual size fractions. This can be
verified by examining the report cited above. Notice, of course, that the
same simplification does not hold for the composite since that calculation
involves summing over s as well.
The calculations for undersize material in overflow stream and over-
size material in the underflow stream are closely related. If a given size
fraction x = (S ,S . ) has a value of S . which is less than the screen
max mm mm
size, then the undersized material, in the overflow stream equals the amount
of material in the overflow stream in that size fraction and the oversized
material in the underflow stream is zero. Inversely, if S . is greater than
or equal to the screen size then the undersized material in the overflow stream
is zero and the oversized material in the underflow stream equals the amount
of material in the underflow stream in that size fraction. The composite values
equal the sums of the individual size fraction values.
7.4.3 Washing Measures
The same measures are used for the washing,two-stage washing, and
froth flotation unit operations. These will be referred to as the washing
measures. Of all the unit performance measures, the washing measures are by
far the most complex. They are as follows.
(1) percent actual recovery
(2) percent theoretical recovery
(3) recovery efficiency percent
(4) percent Btu recovery
(5) percent ash error
(6) float in refuse, percent in product
(7) sink in clean coal, percent in product
(8) total misplaced material, percent of feed
(9) near gravity 0.1 material, percent of feed
144
-------
(10) specific gravity of separation
(11) probable error, specific gravity
(12) imperfection
(13) error area
(14) distribution, percent to washed coal, by specific
gravity fraction.
The actual recovery percent is simply the material in the clean
output flow as a percent of the material in the feed. This is shown mathe-
matically in (6) .
I F /Z FT x 100) (6)
SC,l,s,ggI,l,s,g )
Using the concentrating table as an example, shown on User Handbook Example
page 37 (p. 190), the actual recovery percent value for the size fraction 1/2 by 8M
is derived as shown in (7).
(103.0 x .513)7(169.7 x .449) x 100 = 69.3 (7)
Given rounding errors, this is the reported value. Notice that the composite
actual recovery percent is equal to the yield percent given for the concentrating
table as shown on the summary data for units table. This is as expected.
The value for percent theoretical recovery is somewhat more complicated.
It is based on the percent ash in the clean output stream. The theoretical
recovery percent for a given size fraction or composite equals the percent of
material in the feed, in the relevant fraction which has a percent ash less
than or equal to the percent ash in that fraction in the clean output flow.
It is estimated by plotting the cumulative percent ash versus the cumulative
weight and then reading off that weight value corresponding to the percent ash
for the clean.
145
-------
Using linear interpolation, the value of the theoretical recovery
for the 1/2 by 8M size fraction would be calculated as follows. The percent ash
in that size fraction, from page 36, Appendix A (p. 189), is 6.41. Turning now
to the specific gravity analysis for the feed on page 34, Appendix A (p. 187),
examine the cumulative percent ash and weight columns for that size fraction.
The value 6.41 is between the values of 5.53 and 6.63 which have corresponding
weight percent values of 67.28 and 71.12. The calculation of theoretical re-
covery is
(71.12 - 67.28)7(6.63 - 5.53) x (6.41 - 5.53) + 67.28 = 70.35 (8)
The value varies slightly from the reported value of 70.5 because the program
uses a more complicated routine than linear polynomial interpolation; however,
the above should adequately demonstrate the calculation.
Recovery efficiency simply equals the actual recovery divided by the
theoretical recovery times 100. Btu recovery is also easy. Its calculation
is
100 * (I 'c.b.s.g'I FI,b,s,g) ^
Ash error is the numerical difference between the actual and the-
oretical ash contents of washed coal at the yield of washed coal obtained.
The calculation of the theoretical ash contents of washed coal at the yield
of washed coal obtained proceeds much like the calculation of theoretical
recovery. It is computed by plotting the cumulative weight versus the cumu-
lative percent ash and then reading off that ash value corresponding to the
actual recovery percent for the clean. It was observed earlier that actual
recovery percent and percent yield were the same. Using the same example
as before, the theoretical ash value is calculated in (10)"
(6.63 - 5.53)7(71.12 - 67.28) x (69.4 - 67.28) + 5.53 = 6.14 (10)
Now, subtracting this value from the actual clean ash content percent of
6.41 gives the ash error value of 0.3 which is the reported value.
146
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The values for float in refuse, percent in product; sink in clean
coal, percent in product; and total misplaced material, percent of feed are
all closely related. Their calculation is a bit complex since estimation is
required; however, intuitively they are quite simple. All are based on the
specific gravity of separation. The term float refers to that material whose
specific gravity is less than the specific gravity of separation; while the
term sink refers to that material whose specific gravity is greater than or
equal to the specific gravity of separation. The notions of float in refuse
and sink in clean refer to the fact that if perfect separation were achieved
by the unit then all float in the feed would go to clean and all sink in the
feed would go to refuse. The value float in refuse, percent in product, then,
is the percent by weight of the total material in the refuse which is float.
Equivalently, the value sink in clean coal, percent in product, is the percent
by weight of the total material in the clean coal which is sink. In some
sense, the sink in clean and float in refuse can be thought of as having been
misplaced; therefore, the value total misplaced material, percent of feed, is
the percent by weight of the total material in the feed which was misplaced
in the output flows.
The values reported under near gravity 0.1 material, percent of
feed, simply represent that percentage of material in the feed which is within
;+ 0.1 specific gravity units of the specific gravity of separation. The
calculation itself is complex. It should be pointed out that all of the
calculations of these measures make heavy use of the uniformity assumption
discussed earlier primarily in terms of size fractions. The application of
this assumption to specific gravity distributions is similar. To demonstrate
it, the calculation of a particular value of near gravity 0.1 material is
presented here. The user handbook example on page 22, Appendix A (p. 175), shows a
near gravity value of 11.3 for the 6 by 2 inch size fraction. That page also
shows a specific gravity of separation for that size fraction of 1.53. The
near gravity range, then, is 1.43 to 1.63. The problem is to compute that
proportion of the material in the feed in the 6 by 2 inch size fraction which
is in the specific gravity range of 1.43 to 1.63.
147
-------
Turning now to page 20 of the User Handbook Example, Appendix A
(p. 173), notice that the following direct percent weight values are shown
for the 6 by 2 inch size fraction for the flowstream whose destination is
the jig.
Specific
gravity
1.40 - 1.50
1.50 - 1.60
1.60 - 1.70
weight
11.23
2.91
2.07
(11)
The problem is to compute that percent of the material in the 1.40 - 1.50
fraction which is in the fraction 1.43 - 1.50 and to compute that percent in
1.50 - 1.70 which is 1.60 - 1.63. Using the uniformity assumption, the
calculations are simply
(1.43 - 1.50)7(1.40 - 1.50) = .7 (12)
(1.60 - 1.63)7(1.60 - 1.70) = .3
These calculations are based entirely on the definitions of the specific gravity
fractions. They take no characteristics of the flowstream into account. The
calculation of near gravity material is now
(0.7 x 11.23) + 2.91 + (0.3 x 2.07) = 11.39 (13)
The difference from the reported value is due to roundoff.
The next performance measure reported for the washing, two-stage
washing, and froth flotation unit operations is the specific gravity of
separation. This value already has been discussed extensively.
The probable error, specific gravity, is one-half of the specific
gravity interval spanned by the distribution curve in passing from the 25
percent to 75 percent recovery ordinates. To calculate this value, the program
uses 4-point lagrangian interpolation over the actual distribution curve cal-
culated. As such, the calculation is straightforward. Occasionally the
results shown for this value will be slightly negative. This is of course,
impossible since all distribution curves are monotone decreasing. The negatives
are produced because of the manner in which interpolation is performed.
Eventually, this problem should be corrected.
148
-------
Imperfection is the ratio of probable error divided by the specific
gravity of separation or by the specific gravity of separation minus one. As
discussed in the previous chapter, the offset for the denominator of the im-
perfection calculation is specified by the user in the equipment inventory
definition.
Error area is based on the notion of perfect separation, much as
the notions of float and sink were; however, it is based purely on the shape
of the distribution curve. Geer and Yancey^ ' describe its calculation
as follows (page 18-12):
Since the distribution curve for a perfect separation
would show all material lighter than the specific gravity of se-
paration reporting to washed coal and all heavier material re-
porting to refuse, it would be composed of three straight-line
segments. One segment would be on the 100-percent recovery axis,
one would comprise the specific gravity of separation abscissa,
and the third would lie on the 0 percent recovery axis. The
area lying between this curve for a perfect separation and the
distribution curve actually obtained is, like probable error,
a measure of sharpness of the separation."
This area is called error area. Its physical calculation is complex and will
not be described here.
The remaining values shown are the actual distribution curve values,
shown as percentages, which were used for the separation. The computation is
these values has been described extensively in previous parts of this report.
7.4.4 Rotary Breaking Measures
There are three unit operation specific performance measures associated
with the rotary breaking.
(1) coal product/coal feed, percent
(2) coal in overflow stream, percent
(3) rock in underflow stream, percent
The first measure is 1 minus the proportion of material that will not pass
through the holes in the breaker times 100. It is, thus, equivalent to the
weight ratio underflow to feed percent value reported for the screening unit
operations. The coal in the overflow stream is that percent of the refuse
stream which is coal and the rock in the underflow stream is that percent of
the clean stream which is rock.
149
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7.5 Summary Data for Units Reports
The summary data for units report is intended to describe the over-
all results of the simulation for the units. It is issued after the simula-
tion has been run. In addition to the basic unit description, it shows the
yield and Btu recovery, both in percent form, for each unit.
150
-------
7.6 Summary Data for Flowstreams Report
The summary data for flowstreams report is intended to describe the
overall results of the simulation for the flows. It is issued after the
simulation has been run. Its -content is self-explanatory.
151
-------
8.0 REFERENCE LIST FOR VOLUME I
(1) Gottfried, B.S., Jacobsen, P.S., and Vaillant, A., "Computer Analysis
of Coal Plant Performance", presented at the 14th International
Symposium on the Application of Computer Methods in the Mineral
Industries, The Pennsylvania State University, Pittsburgh, Pennsylvania,
(October 1976).
(2) Humphreys, K.K., Leonard, J.W., and Buttermore, J.A., "Computers for
Coal-Part X", Coal Age,
(3) Isaacs, G.A., Letter dated 10/5/76 containing output data from two
coal programs and a description of the cleaning plant configuration
index used, PEDCo-Environmental Specialists, Inc., Cincinnati, Ohio.
(4) Walter, A.D., "A Computer Simulation Model for Coal Preparation Plant
Design and Control", Unpublished Master's of Engineering Thesis,
Pennsylvania State University, Department of Mineral Engineering,
Pittsburgh, Pennsylvania, 1976.
(5) Holt, E.G., Jr., "An Engineering/Economic Analysis of Coal Preparation
Plant Operation and Cost", Report for U.S. Department of Energy, Contract
ET-75-C-01-9025, The Hoffman-Muntner Corp., Silver Spring, MD (February
1978).
(6) Vaillant, A., "Modelling Crushers, Breakers, and Screens for Use in
Computer Simulation of Coal Preparation Plants", Report for U.S. Bureau
of Mines, Grant GO-155030.
(7) Gottfried, B.S., "A Generalization of the Distribution Data for
Characterizing the Performance of Float-Sink Coal Cleaning Devices",
Unpublished paper, University of Pittsburgh, Pittsburgh, Pennsylvania.
(8) Gottfried, B.S. and Jacobsen, P.S., "A Generalized Distribution Curve
for Characterizing the Performance of Coal Cleaning Equipment", Bureau
of Mines RI (in preparation).
(9) Deurbrouck, A.W. and Hudy, J., "Performance Characteristics of Coal-
Washing Equipment: Dense-Medium Cyclones", U.S. Bureau of Mines, RI 7673,
1972.
(10) Broadbent, S.R. and Calcott, T.G., "Coal Breakage Processes", Journal
of the Institute of Fuel, London, England,'December, 1956.
Coal Preparation. Edited by J.W. Leonard and D.R. Mitchell, AIME,
(Geer, M.R. and Yancey, H.F.) "Plant Performance and Forecasting Cleaning
Results", New York (1968), Chapter 18, pp 18-1 through 18-29.
152
-------
APPENDIX A
USER HANDBOOK EXAMPLE
153
-------
USER HANDBOOK EXAMPLE PAGE 1
I-1
Ln
.P-
UNIT NUMBER
1
^
3
<»
5
6
7
a
9
10
11
13
13
l«t
15
16
17
18
UNIT TYPE
11 (ROTARY BREAKER!
<•! (BLENDE* (ADOS WATER))
23 IHET UPPER SCREEN)
2<« (HET LOWER SCREEN)
««1 (STREAM BLENDER)
6 (TWO-STAGE 8AUM JIG)
M (STREAM BLENOER)
16 (SECONDARY MULTIPLE ROLL CRUSHER)
<»1 (STREAM OLENOER)
33 (WET SINGLE DECK SCREEN)
1 (CONCENTRATING TABLE)
<»1 (STREAM BLENOER)
7 (FROTH FLOTATION CELL1
«fl (STREAM BLENDER)
52 (CENTRIFUGE)
41 (STREAM BLENDER)
1.1 (STREAM BLENOER)
52 (CENTRIFUGE)
DECISION VARIABLES
20.000 12.000 6.000
1.500
0.500
1.620
0.275
0.023
1.580
99.000
99.000
-------
USER HANDBOOK EXAMPLE PAGE 2
FLOWSTREAM NUMBER
1 (FEED»
2
3
5
6
7
8
9
10
11
12
13
15
16
17
18
19
20
23
25
26
ORIGIN - UNIT NUMBER
0
1 C
2
DESTINATION - UNIT NUMBER
1
2
3
1
3
3
«.
<*
5
6
6
6
7
8
9
10
10
11
11
12
13
13
!<*
15
15
16
R
U
L
U
L
U
C
M
R
R
M
M
U
L
C
R
R
C
R
R
U
t
C
7
5
"
5
9
6
17
8
7
12
9
10
11
13
16
12
Hi
16
Ik
15
0
2
17
-------
USER HANDBOOK EXAMPLE PAGE 3
FLOH3TREAM N'JIBER
Z7
29
29
ORIGIN - UNIT NUMBER
17 C
18 U
18 L
DESTINATION - UNIT NUMBER
18
0
Z
-------
rEED TO UNIT NUMBER 1
SPECIFIC GRAVITY ANALYSIS OF FLOWSTFEAM NUMBER 1
USER HfrNOBOOK EXAMPLE PAGE
SIZE FRACTION AND HEIGHT
18 8Y 12
OF FLOW 7,1
12 BY 6
PERCENT OF FLOW
6 BY 2
PERCENT OF FLOW 32.2
Z BY 1/2
PERCENT OF FLOW
13. 1
1/2 BY 8M
PERCENT OF FLOW
1 3. 0
SPECIFIC
GRAVITY
FLOAT-1 . 30
i
1
1
1
1
1
1
.30-1 . 35
.35-1. 1.0
.1, 0-1. 50
.50-1. 60
.60-1 . 70
.70-1. 80
.80-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
,35-1. 1,0
.1,0-1. 50
.50-1. 60
.60-1. 70
.70-1 . 80
.80-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1. 1,0
.1* 0-1. 50
.50-1. 60
.60-1. 70
.70-1.80
.eO-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1.1.0
.1*0-1. 50
.50-1. 60
.60-1. 70
.70-1. «0
.80-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1. i+O
.1*0-1. 50
.50-1. 60
.60-1. 70
.70-1.80
.80-SINK
WEIGHT
19.
11.
2.
11.
2.
1.
0.
51.
16.
H*.
5.
5.
!*.
2.
1.
50.
21.
11.
2.
12.
1.
1.
0.
1*8.
22.
19.
6.
7.
l*.
2.
1.
35.
33.
23.
7.
6.
3.
1.
1.
22.
70
00
10
30
10
90
80
10
72
31
31
31
10
10
20
95
39
85
21
15
91
71
70
09
Qi«
9'*
91
52
51
20
60
27
50
07
52
92
21
81
50
0.30
0.37
5.03
0. 79
1. 07
1.10
1.23
,26
, 35
,1*2
10.52
0.60
0.99
1. 09
1. 22
1.33
1.56
10. 01
0.80
0.99
1.1*1
1.1.8
1.59
1. 65
10.95
0. 77
0.87
0.95
1. 08
1.19
,28
t»0
7.97
0. 61.
0. 66
0.69
0. 71*
0.79
0,,8
-------
FEED TO UNIT NUMBER 1
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 1 (CONTINUED)
USER HANDBOOK EXAMPLE PAGE 5
SIZE FRACTION AND WEIGHT
8M BY 28M
PERCENT OF FLOW 5.6
28M BY 100M
PERCENT OF FLOH
3.2
Ln
O3
100M BY 325M
PERCENT OF FLOH
2. 6
COMPOSITE
FLOHRATE
500.0
SPECIFIC
GRAVITY
FLOAT-1.30
1.30-1. 35
1.35-1.40
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 1.0
1.1(0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 60
1.80-SINK
FLOAT-1, 30
1.30-1.35
1.35-l.itO
l.i»0-1.50
1.50-1.60
1.60-1.70
1.70-1.60
1.80-SINK
DIRECT, PERCENT
WEIGHT
1.7.99
19.1.8
5. 82
4.92
2.31
1.1.1
1.10
16.97
59. 00
12.50
8.50
4.20
2. 00
1. 00
0.60
12.20
36. 36
23.98
15.58
5.59
2.30
1.00
0.50
11*. 69
21*. 95
15.65
I*. 99
8.38
2.98
1.83
1.06
1*0.16
ASH
1.80
<».30
8.80
15.1*0
2l».<»0
33.30
1.1.70
82.80
1.80
6.1.0
8.30
15.50
22.80
28. "*0
3i«. 30
67.70
1.20
2.70
if. 20
11. 00
17.60
2i». 10
32.20
67.30
2.1*5
i». 57
8.69
15.58
25.57
33.08
<»2.37
83.46
PYRITIC
SULFUR
0. 20
0.1*8
1.00
1.50
2.20
3.1.5
6.28
21. 02
0.16
0.73
1.02
2.05
3.27
4.51
6.1*1.
20.1.3
0.10
0.23
0.1.1
l.li*
2.38
l*.09
7.i»i*
25.60
O.li.
0.1.9
0.88
1.51*
2.09
3.47
5.1.6
18.91
TOTAL
SULFUR
0.68
0.98
1.50
2. 02
2.67
4.06
6.70
21.72
0.73
1.21*
1.1*9
2.63
3.73
5.17
7.22
21.1.1
0.64
0.8<*
1. 01
1. 66
2.98
1..32
8.06
26.50
0.71.
1. 09
1.1*2
2.11
2.56
i*.00
5.95
20.02
BTU/L8
15,355
li*, 907
13,909
12,682
11,077
9,723
8,269
1,563
1 5,355
li»,907
13,909
12,662
11,077
9,723
8,269
1,563
15,355
lit, 907
13,909
12,682
11,077
9,723
8,269
1,563
15,355
li», 907
13,909
12,682
11,077
9,723
8,269
It 563
HEIGHT
1.7.99
67.1*7
73.29
78.21
80.52
81.93
83. 03
100.00
59.00
71.50
80.00
8i«.20
86.20
87.20
87.80
100.00
36.36
60.31*
75.92
81.52
83.82
81*.82
85.31
100.00
2i».95
1*0.61
45.59
53.97
56.95
58.78
59.81.
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL BTU/LB
SULFUR SULFUR
1.80
2.52
3.02
3.80
i*.39
1..69
5.38
18.51
1.80
2.60
3.21
3.82
l*.26
I..51*
4.74
12.1*2
1.20
1.80
2.29
2.89
3.29
3.5<*
3.70
13.0<*
2.1.5
3.27
3.86
5.68
6.72
7.5«.
8.16
38.1.0
0.20
0.28
Or34
0.1*1
0.1.6
0.51
0.59
4.06
0.16
0.26
0.31*
0.1*3
0.1.9
0.5
-------
USER HANDBOOK EXAMPLE PAGE
SUMMARY 3F THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 1
ROTARY BREAKER
LENGTH =20.00 rEET DIAMETER = 1Z.OO FEET SIZE CF OPENING =6.00 INCHES
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
FEED (COAL * ROCK)
UNDERFLOW (PRODUCT) STREAM.
OVERFLOW (REFUSE) STREAM...
ASH, PERCENT
FEED (COAL + RCCO
UNDERFLOW (PRODUCT) STREAM.
OVERFLOW (REFUSE) STREAM...
.'YRITIC SULFJR, PERCENT
FEED (COAL * ROCK)
imERrLOW (PR3CUCT) STREAM.
OVERFLOW (REFUSE) STREAM...
TOTAL SULFUR, PERCENT
FEED ( CO&L * RCCO .........
UNDERFLOW (PRODUCT) STREAM.
OVERFLOW (REFUSE) STREAM...
3TU/L8, MOISTURE FREE
FEED (COAL + ROCKI
UNDERFLOW (PR3CUCT) STREAM.
OVERFLOW (REFJSE) STREAM...
COAL PRCOUCT/COAL FEED PERCENT
COAL IN OVERFLOW STREAM DD
ROC< IN UNDERFLOW STREAM DO
18
BY
12
7. G6
0.00
23.20
47.62
0.00
97.73
9. 81
J.OO
0.43
10.52
0.00
3.46
7,672
0
333
0.0
2.5
0.0
12
BY
6
23. 14
0. 00
76. 80
47. 16
0. 00
94. 54
0. OC
0.97
10.01
0.03
1.C5
7,666
0
795
0.0
6.0
O.C
6
BY
2
32.16
0.00
39.21
G.QO
10.20
11.07
0.00
10.95
11.95
0.00
8,035
8,912
0
100.0
0,0
33. 6
2
BY
22.15
OoOO
35.07
26.94
0.00
6.75
10.28
o.on
7,97
11.52
o.oa
9,670
10, 778
0
100.3
0.0
19, 7
1/2
BY
8M
13.04
17.54
0.00
24.70
22.69
O.OG
5.03
7.01
u. 00
5.62
7.79
C.Ofl
11,514
11,698
C
100. G
0.0
15.8
8M
BY
28M
5.59
7.47
0.00
18.51
17.52
o.co
4.06
5.29
O.OD
4.58
5.93
o.oc
12,456
12,555
0
100.0
0.0
11.9
28M
BY
100M
3.24
4.34
J.OO
12.42
12.01
0.00
3.00
3.92
C.OO
3.60
4.57
0.00
13,197
13,289
0
100.0
0.0
7.0
100M
BY
325M
2.65
4. 02
0. 00
13. 04
11.34
0. 00
4.12
4.25
0. 00
4. 73
4. 88
0. 03
12,657
13,035
0
100.0
O.G
7.5
COMP
100. 00
100.00
100.00
38.40
29.68
95.28
8.06
9.17
0.84
8.86
10.37
5.92
9,145
10 ,442
693
99.0
5. 2
23.6
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 2
ORIGIN - UNIT NUMBER 1 C DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 7
SIZE FRACTION AND HEIGHT
6 BY 2
PERCENT OF FLOW
44.5
2 BY 1/2
PERCENT OF FLOW
22.1
1/2 BY 8M
PERCENT OF FLOW
17.5
8M BY 28M
PERCENT OF FLOW
7.5
28M BY 100M
PERCENT OF FLOW
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER Z (CONTINUED)
ORIGIN - UNIT NUMBER 1 C DESTINATION - UNIT NUMBER 2
USER HANDBOOK EXAMPLE PAGE 8
SIZF FRACTION AND HEIGHT
100M BY 325H
PERCENT OF FLOW i». o
COMPOSITE
FLOHRATE
1*33.5
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1. 1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1.1*0
1.
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 4
ORIGIN - UNIT NUMBER 1 R DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PACK 9
SIZE FRACTION AND WEIGHT
18 BY 13
PERCENT OF FLOW
23. 3
13 9Y 6
PERCENT OF FLOW
76. a
COMPOSITE
FLOWRATE
66.5
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1.70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1.50
1.50-1. 60
1.60-1.70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
HEIGHT
0.85
0.46
0. 09
0.49
0. 09
0. 06
0. 03
97.88
1. 83
1.38
0.45
0.74
0.36
0.31
0. 11
94.93
1.60
1.17
0.37
0.68
0.30
0.18
0. 09
95.61
ASH
3.80
4.40
7.80
15.40
35.00
31.50
41.00
99.65
3.87
4.63
9.17
16.08
36.39
34.09
44.65
99.08
3.86
4.60
9.09
15.97
36.30
33.83
44.34
99.21
PYRITIC
SULFUR
0.31
0. 71
0.98
1.10
1.44
3.90
5.46
0 .43
0.19
0.64
1 .04
1.33
1.87
3.14
5.93
0.97
0.19
0.65
1. 04
1.38
1.84
3.11
5.89
0.04
TOTAL
SULFUR
0.79
1.57
1.59
1.60
1.84
3.50
6.13
0.44
0.80
1.31
1.64
1.85
3.36
3. 70
6.46
1. 03
0.80
1.33
1.64
1.81
2.33
3.68
6.44
0.69
BTU/LB
15,355
14,907
13,909
13,683
11,077
9,733
8,369
35
15,355
14,907
13,909
13,683
11,077
9,733
8,269
87
15,355
14,907
13,909
12,683
11,077
9,723
8,369
75
HEIGHT
0.85
1.33
I.
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 3
ORIGIN - UNIT NUMBER 2 DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 10
SIZE FRACTION AND WEIGHT
12 8Y 6
PERCENT OF FLOW
0.1
6 BY 2
PERCENT OF FLOW
44.2
2 3Y 1/2
PERCENT OF FLOW
22.2
1/2 BY 8M
PERCENT OF FLOW
1?. 6
8M BY 28M
PERCENT OF FLOW
7.6
SPECIFIC
GRAVITY
FLOAT-1.30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1. 1*0
l.l.Q-1. 50
1.50-1.60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.1)0-1. 50
1.50-1. 60
1.60-1. 70
1 .70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1.50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 40
1.40-1. 50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
1.68
1.25
0.40
0. 70
0.32
0. 19
0.10
95. 35
22.29
14. 09
3.54
11.23
2.91
2. 07
0.97
42.90
2S.19
20.15
6.51
9.97
4.64
2.55
1.57
29.43
32.31
22.76
7.34
8. 26
3.68
2. 09
1.55
22. 03
43.91
20. 75
6.35
6.21
2.87
1.72
1.29
16.89
DIRECT, PERCENT
ASH PYRITIC
SULFUR
2.86
4.61
9.12
16. 01
26.34
33.93
44.47
99.16
2.83
4.50
8.62
15.54
25.78
32.75
42.99
79.45
2.62
4.64
9.35
15.92
26.02
33.81
43.01
69.61
2.47
4.75
9.59
15.75
25.82
33. 75
41.92
75.21
1.95
4.44
9.05
15.56
25.02
33.46
41.88
75.68
0.19
0.65
1. 04
1.30
1.86
3.12
5.91
0.89
0.15
0.64
1.13
1.74
2.24
3 .63
5. 76
24.47
0.15
0.55
1.00
1.52
2. 06
3.46
5.69
32.65
0.10
0.23
0.59
1.00
I .69
3.03
4.39
30.04
0.18
0.41
0.88
1.34
2.03
3.33
5.66
29.19
. TOTAL
SULFUR
0.80
1.32
1.64
1.82
2.33
3.69
6.45
0.94
0.60
1.31
1. 73
2.33
2.77
4.24
6.40
25.68
0.78
1. 12
1.51
2. 08
2.52
3.98
6. 21
35.48
0.67
0.81
1. 07
1.53
2. 10
3.36
4.66
31.67
0.68
0.94
1.38
1.87
2.48
3.85
6.05
30.54
BTU/LB
15,355
14,907
13,909
12,682
11,077
9,723
8,269
79
15,355
14,907
13,909
12,682
11,07?
9,723
8,269
2,016
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2,841
15,355
14,907
13,909
12,682
1 1,077
9,723
6,269
2,397
15,355
14,907
13,909
12,682
11,077
9,733
8,269
ZiZIZ
HEIGHT
1.68
2.93
3.33
4. 03
4.35
4.55
4.65
100.00
22.29
36.38
39.91
51.14
54. 06
56.13
57.10
100.00
25.18
45. 33
51.84
61.81
66.45
69. 00
70.57
100.00
32.31
55.07
62.40
70.66
74.34
76.43
77.97
100.00
43.91
64.67
71.02
77.23
80.11
81.83
83.11
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
2.86
3.61
4.26
6.31
7.79
8.90
9.67
95.01
2.83
3.48
3.93
6.48
7.52
8.45
9. 04
39.25
2.62
3.52
4.25
6.14
7.52
8.49
9.26
27.02
2.47
3.41
4.14
5.50
6.50
7.25
7.93
22.75
1.95
2.75
3.31
4.30
5.04
5.64
8.20
17.93
0.19
0.39
0.46
0.61
0.70
0.80
0.91
0.89
0.15
0.34
0.41
0.70
0.73
0.89
0.97
11,06
0.15
0.33
0.42
0.59
0.70
0.80
0.91
10.25
Q.10
0. 15
0.20
0.29
0.36
0.44
0.52
7.02
0.18
0.26
0.31
0.39
0.45
0.51
0.59
0.80
1.02
1.09
1.22
1.30
1.40
1.51
0.97
0. 80
1.00
i. 06
1.34
1.42
1.52
1.60
11.93
0,78
0.93
1. 01
1.18
1.27
1. 37
1.48
11.49
0. 67
0. 73
0. 77
0.86
0.92
0.99
1. 06
7.80
0.68
0. 77
0. 82
0.91
0.96
1.02
1,10
6. 07
BTU/LB
15,355
15,164
15,014
14,609
14,347
14,152
14,025
727
15,355
15,181
15,069
14,545
14,358
14,187
14,086
8,908
15,355
15,156
14,999
14,625
14,378
14,206
14,074
10,768
15,35-5
15,170
15,022
14,748
14,567
14,434
14,312
11,687
15,355
15,211
15,095
14,901
14,764
14,657
1««,559
12,484
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 3 (CONTINUED)
ORIGIN - UNIT NUMBER 2 DESTINATION - UNIT NUMBER 3
USER HANDBOOK EXAMPLE PAGE 11
SIZE FRACTION AND HEIGHT
28M BY 100M
PERCENT OF FLOH
4.4
100M 9Y 325M
PERCENT OF FLOW
t.0
COMPOSITE
FLOHRATE
438.6
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.1*0-1. 50
1.50-1.60
1.60-1. 70
1.70-1.60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. BO
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1. 40
1.40-1.50
1.50-1.60
1.60-1.70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
HEIGHT
54.74
15.42
8. 09
5.09
2.41
1.31
0.86
12. 07
41.17
22.53
13.80
5.66
2.42
1.14
0.64
12.65
28.49
17.85
5.69
9.55
3.38
2.08
1.21
31.75
ASH
1.86
5.61
8.52
15.55
23.81
30.71
38.13
64.40
1.43
3.21
4.86
12.16
19.47
26.63
35.16
62.19
2.45
4.57
8.69
15.53
25.56
33.07
42.35
76.28
PYRITIC
SULFUR
0.16
0.58
0.97
1.73
2.73
3.95
5.90
29.39
0.12
0.33
0.49
1.26
2.42
3.97
6.75
30.85
0.14
0.49
0.88
1.55
2.09
3.48
5.45
'7.15
TOTAL
SULFUR
0.72
1.10
1.44
2.29
3.19
4.53
6.47
30.84
0.66
0.88
1.07
1.79
2.98
4.31
7.33
32. 05
0.74
1.09
1.41
2.11
2.57
4.00
5.95
28.75
9TU/LB
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2,285
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2,027
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2,242
HEIGHT
54.74
70.16
78.25
83.35
85.76
87.07
87.93
100.00
41.17
63.69
77.49
83.15
85.57
86.71
87.35
100.00
28.49
46.34
52.03
61.58
64.96
67.04
68.25
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
1.86
2.68
3.29
4.04
4.59
4.98
5.31
12.44
1.43
2.06
2.56
3.21
3.67
3.97
4.20
11.54
2.45
3.26
3.86
5.67
6.71
7.53
8.15
29. 76
0.16
0.25
0.33
0.41
0.48
0.53
0.53
4.06
0.12
0.19
0.25
0.32
0.37
0.42
0.47
4.31
0.1'*
0.28
0.34
0.53
0.61
0.70
0.78
9.16
0.72
0.80
0.87
0.96
1.02
1.07
1.12
4. 71
0.66
0.74
0.80
0.87
0.93
0.97
1.02
4.94
0.74
0.88
0.93
1.12
1.19
1.28
1.36
10.06
BTU/LB
15,305
15,257
15,117
14,968
14,859
14,782
14,718
15,355
15,197
14,967
14,812
14,706
14,641
14,594
13,004
15,355
15,182
15,043
14,677
14,490
14*342
14,234
10,427
-------
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 3
WET UPPER SCREEN
SIZE OF OPENING = 1.50 INCHES
USER HANDBOOK EXAMPLE PAGE
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
FEED
ASH, PERCENT
PYRITIC SULFUR, PERCENT
FEED.
OVERFLOW (COARSE) STREAM......
UNDERFLOW «FINE» STREAM.
TOTAL SULFUR, PERCENT
FEED.
OVERFLOW (COARSE* STREAM
BTU/LB, MOISTURE FREE
FEED ......... o. . . o
WEIGHT RATIO, UNOERFLOH TO FEED.... PERCENT
3TU RATIO, UNOERFLOH TO FEED....... DO
UNDERSIZE MATERIAL IN OVERFLOW STREAM. 00
OVERSIZE MATERIAL IN UNDERFLOW STREAM. DO
6
3Y
2
1.1.. 22
8l». 3<»
0.00
39.25
39.25
0.00
11. 06
11. 06
0. 00
11.93
11.93
0. 00
8,908
8,908
0
0. 0
0.0
0.0
0.0
2
BY
1/2
22.15
15.1.9
29.50
27.02
27.02
27.02
10.25
10.25
10.25
11 .1.9
11.1.9
11. 1.9
10,768
10,768
10,766
63.3
63.3
15.5
0.0
1/2
BY
8M
17.57
0.02
36.91
22. 75
22.75
22.75
7.02
7.02
7. 02
7.80
7.80
7 .80
11,687
11,687
11,687
99.9
99.9
0.0
0.0
8M
BY
28M
7.56
0.00
15.88
17.93
17.93
17.93
5.1.2
5.1.2
5.1.2
6.07
6.07
6.07
12, <.8l»
12«i»8. 06
k. 06
it. 06
<». 71
l± Q £.
ft _ Q It
13,001.
139 OQi.
13,OQi»
100.0
iQO.O
0.0
0.0
COMP
100.00
100.00
100.00
29.78
37.1.3
21.35
9.16
10.91
7.22
10. 06
11.85
8.09
10,1.27
9,185
11,795
1.7.6
53.6
15.5
0.0
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 5
ORIGIN - UNIT NUMBER 3 U DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 13
SIZE FRACTION AND HEIGHT
12 BY 6
PERCENT OF FLOW
0.1
6 BY 2
PERCENT OF FLOW
81.. 3
2 BY 1/2
PERCENT OF FLOW
15.5
COMPOSITE
FLOWRATE
229.9
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.<«0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.i«0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
HEIGHT
1. 68
1.25
0.1*0
0.70
0. 32
0. 19
0. 10
95. 35
22.29
11*. 09
3. 5i»
11.23
2.91
2. 07
0.97
1*2.90
25.18
20.15
6.51
9.97
<*. 6i*
2.55
1.57
29.1*3
22. 71
15. 01
3.99
11.02
3.18
2.11.
1.06
1*0.88
DIRECT, PERCENT
ASH PYRITIC
2.86
l*.61
9.12
16.01
26.31*
33.93
1*1*. <*7
99.16
2.83
4.50
8.62
15.51*
25.78
32.75
1.2.99
79.45
2.62
<>.6l*
9.35
15.92
26.02
33.81
1*3.01
69.61
2.79
i».53
8.81
15.59
25.83
32.95
1.3.00
78.42
SULFUR
0.19
0.65
1 . 01*
1.30
1.86
3. 12
5.91
0.89
0.15
0.61*
1.13
1.71.
2.2i*
3.63
5. 76
21*. 1*7
0.15
0.55
1.00
1.52
2.06
3.<*6
5.69
32.65
0.15
0.62
1.10
1.71
2.20
3.60
5.75
25.31
TOTAL
SULFUR
0.80
1.32
1.61*
1.82
2.33
3.69
6.1*5
0.91*
0.80
1.31
1.73
2.33
2.77
4.24
6.1*0
25.68
0.78
1.12
1.51
2.08
2.52
3.98
6.21
35.1.8
0.80
1.27
1.68
2.29
2.71
4.20
6.35
26.69
BTU/LB
15,355
1"*, 907
13,909
12,682
11,077
9,723
8,269
79
15,355
li«,907
13,909
12,682
11,077
9,723
8,269
2,016
15,355
li»,907
13,909
12,682
11,077
9,723
8,269
2,61*1
15,355
li*, 907
13,909
12,682
11,077
9,723
6,269
2,101
HEIGHT
1.68
2.93
3.33
i*.03
i*.35
i».55
i*.65
100.00
22.29
36.38
3S.91
51.11*
51*. 06
56.13
57.10
100.00
25.18
1*5.33
51.8<*
61.81
66.45
69. 00
70.57
100.00
22.71
37.72
1*1.72
52.71*
55.91
58.06
59.12
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
2.86
3.61
i*.26
6.31
7.79
6.90
9.67
95.01
2.83
3.1*8
3.93
6.1*8
7.52
8.i»5
9.01*
39.25
2.62
3.52
i».25
6.14
7.52
8.1.9
9.26
27.02
2.79
3.1*8
3.99
6.1*2
7.52
8.1*6
9.08
37.«t3
SULFUR
0.19
0.39
0.1*6
0.61
0.70
0.80
0.91
0.69
0.15
0.34
0.<»1
0.70
0.78
0.89
0.97
11.06
0.15
0.33
O.i»2
0.59
0.70
0.80
0.91
10.25
0.15
0.31.
0.1*1
0.68
0.77
0.67
0.96
10.91
SULFUR
0. 80
1.02
1. 09
1.22
1.30
1.1*0
1.51
0.97
O.BO
1. 00
1. 06
1.31*
1.42
1.52
1.60
11.93
0.78
0.93
1.01
1.18
1.27
1.37
1.1.8
11.1*9
0.80
0.98
1.05
1.31
1.39
1.1*9
1.56
11.65
BTU/LB
15,355
15,161*
15,011*
11*, 609
11., 3i*7
H., 152
li»,025
727
15,355
15,181
15,069
li., 51*5
Ht, 358
li»,187
H*, 086
6,906
15,355
15,156
li., 999
li»,625
li., 378
lit, 206
li»,07i»
10,768
15,355
15,177
15,055
14,559
11*, 362
1<»,190
14, 081.
9,185
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 6
ORIGIN - UNIT NUM3EK 3 L DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE
SIZE FRACTION AND WEIGHT
2 BY 1/2
PERCENT OF FLOW
29.5
1/2 BY 8M
PERCENT OF FLOW
36.9
8M BY 28M
PERCENT OF FLOW
15.9
28M BY 100M
PERCENT OF FLOW
9.2
100M BY 325M
PERCENT OF FLOW
8.5
SPECIFIC
GSA VITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1.60
1.60-1.70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.i»0
1.40-1.50
1,50-1. 60
1.60-1.70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 40
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.60
1.80-SINK
FLOAT-1. 30
1.3C-1. 35
1.35-1.40
1.1*0-1.50
1.50-1. 60
1 .60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.40-1. 50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
25. 18
20. 15
6.51
9.97
i*. 64
2.55
1.57
29.1.3
32.31
22.76
7.3i«
8. 26
3.68
2. 09
1.55
22. 03
1*3. ,1
20.75
6. 35
6.21
2. 87
1.72
1.29
16.89
5i*. 7i»
15.42
8. 09
5. 09
2.41
1. 31
0. 86
12. 07
<»1. 17
22.53
13.80
5.66
2.42
1.1*.
0.64
13.65
DIRECT, PERCENT
ASH PYRITIC
2.62
<*.&<*
9.35
15.92
26.02
33.81
1*3.01
69.61
2.1.7
i».75
9.59
15.75
25.82
33.75
41.92
75.21
1.95
4.44
9.05
15.56
25.02
33.1.6
1*1.88
75.68
1.86
5.61
8.52
15.55
23.81
30.71
38.13
6i*. (»0
1.43
3.21
4.86
12.16
19.1.7
26.63
35.16
62.19
SULFUR
0. 15
0.55
1.00
1.52
2.06
3.1*6
5.69
32.65
0. 10
0.23
0 .59
1. 00
1.69
3.03
4.39
30. ,01.
0.18
0.1.1
0. 88
1.31*
2.03
3.33
5.66
29.19
0.16
0.58
0.97
1. 73
2.73
3.95
5.90
29.39
0.12
0.33
0,1*9
1.26
2.«»2
3.97
6.75
30.05
TOTAL
SULFUR
0.78
1.12
1.51
2.08
2.52
3.98
6.21
35.1*8
0.67
0.81
1. 07
1.53
2.10
3.36
it. 66
31,67
0.68
0.91*
1. 38
1.87
2.1*8
3.85
6. 05
30.51*
0.72
1. 10
l.i*i«
2.29
3.19
4.53
6.47
30.81*
0.66
0.88
1.07
1.79
2.98
4.31
7,33
32.05
3TU/L8
15,355
11*, 907
13,909
12,682
1 1,077
9,723
8,269
2,81.1
15,355
I'M 907
13,909
12,682
11,077
9,723
6,269
2,397
15,355
11., 907
13,909
12,682
11,077
9,723
8,269
2,272
15,355
I'M 907
13,909
12,682
11,077
9,723
8,269
2,285
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2,027
WEIGHT
25. 18
1*5.33
51.81.
61.81
66.1.5
69. 00
70.57
100.00
32.31
55.07
62.40
70.66
71*. 31*
76.43
77.97
100.00
1*3.91
&i*.67
71. 02
77.23
80. 11
81.83
83, 11
100.00
51*.74
70.16
78.25
83.35
85.76
87. 07
87.93
100.00
41.17
63.69
77.1.9
83.15
85.57
86,71
87.35
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
2.62
3.52
4.25
6.14
7.52
8.49
9.26
27.02
2.47
3.41
4.14
5.50
6.50
7.25
7.93
22.75
1.95
2.75
3.31
4.30
5.04
5.64
6.20
17.93
1.86
2.6 8
3.29
4.04
4.59
4.98
5.31
12.44
1.43
2.06
2.56
3.21
3.67
3.97
4.20
11. 5%
0.15
0.33
0.42
0.59
0.70
0.80
0.91
10.25
0.10
0.15
0.20
0.29
0.36
0.44
0.52
7.02
0.13
0.26
0.31
0.39
0.45
0.51
0.59
5.42
0.16
0.25
0.33
0.41
0.48
0.53
0.58
4.06
0.12
0.19
0.25
0.32
0.37
0.42
0.47
4.31
0. 78
0.93
1.01
1.18
1.27
1.37
1.48
11.49
0.67
0.73
0. 77
0.86
0.92
0.99
1.06
7.80
0.68
0.77
0.82
0.91
0.96
02
10
1
1
6. 07
0.72
0.80
0.87
0.96
1.02
1. 07
1. 12
4. 71
0.66
0. 74
0.80
0.87
0.93
0.97
1.02
4.94
BTU/LB
15.355
15,156
14,999
14,625
14,378
14,206
14,074
10,751*
15,355
15,170
15,022
14,748
14,567
14,434
14,312
11,687
15,355
15,211
15,095
14,901
14,764
14,657
14,559
12,484
15,257
15,117
14,968
14,859
14,782
14,718
13,217
15,355
15,197
14,967
14,812
14,706
14,641
14,594
13,004
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 6 (CONTINUED!
ORIGIN - UNIT NUMBER 3 I DESTINATION - UNIT NUMBER
-------
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER
-------
SPECIFIC GRAVITY ANALYSIS OF FLOHSTREAM NUMBER 7
ORIGIN - UNIT NUMBER 4 U DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 17
SIZE FRACTION AND HEIGHT
2 6Y 1/2
PERCENT OF FLOW
92.7
1/2 BY 8M
PERCENT OF FLOW
7.1
8M BY 28M
PERCENT OF FLOH
D.I
COMPOSITE
FLOWRATE
66. it
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.1* 0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1 . 60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1. it 0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
l.i«0-l. 50
1.50-1. 60
1.60-1. 70
1.70-1.60
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1. UO
l.i»0-l. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
WEIGHT
25.18
20.15
6.51
9.97
4.64
2.55
1.57
29.1(3
32.31
22. 76
7. 3k
8.26
3.68
2.09
1.55
22, 03
43.91
20.75
6.35
6. 21
2. 87
1.72
1.29
16.89
25. 72
20.31*
6.58
9.8i«
4.56
2.52
1.56
28.88
ASH
2.62
4.64
9.35
15.92
26.02
33.81
43. 01
69.61
2.47
4. 75
9.59
15.75
25.92
33.75
l»1.92
75.21
1.95
4.44
9.05
15.56
25.02
33. 46
41.38
75.68
2.61
14,65
9.37
15.91
26.00
33.81
42.93
69.92
PYRITIC
SULFUR
0.15
0.55
1. 00
1.52
2. 06
3.1.6
5.69
32.65
0.10
0.23
0.59
1.00
1.69
3. 03
4.39
30.01*
0.18
0.1*1
0.88
1.3<*
2.03
3.33
5.66
29.19
0. 15
0.53
0.97
l.i*9
2.0<*
3.i«3
5.60
32.50
TOTAL
SULFUR
0.78
1.12
1.51
2. 08
2.52
3.98
6.21
35.1*8
0.67
0.81
1. 07
1.53
2.10
3.36
i». 66
31.67
0.68
0.91*
1.38
1.87
2.1*8
3.85
6.05
30.54
0.77
1.10
1.1*8
2.05
2.50
3.95
6.10
35.27
8TU/LB
15,355
1<*,907
13.909
12,682
11,077
9,723
8,269
2,8'*!
15,355
I'M 907
13,909
12,682
11,077
9,723
8,269
2,397
15,355
11*, 907
13,909
12,682
11,077
9,723
8,269
2,272
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2,817
HEIGHT
25.18
1.5. 33
51.8<»
61.81
66.1*5
69.00
70.57
100.00
32.31
55. 07
62.1*0
70.66
7i».34
76.43
77.97
100.00
43.91
64.67
71. 02
77.23
80. 11
81.83
83.11
100.00
25. 72
46. 05
52.63
62.47
67.04
69.55
71.12
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
2.62
3.52
4.25
6.14
7.52
8.49
9.26
27.02
2.47
3.41
4.14
5.50
6.50
7.25
7.93
22.75
1.95
2.75
3.31
4.30
5.04
5.64
6.20
17.93
2.61
3.51
4.24
6.08
7.44
8.39
9.15
26.70
0.15
0.33
0.42
0.59
0.70
0.80
0.91
10.25
0.10
0.15
0.20
0.29
0.36
0.44
0.52
7.02
0.18
0.26
0.31
0.39
0.45
0.51
0.59
5.42
0.15
0.32
0.40
0.57
0.67
0.77
0.88
10.01
0.78
0.93
1. 01
1.18
1.27
1.37
1.48
11.49
0.67
0.73
0.77
0.86
0.92
0.99
1.06
7.80
0.68
0.77
0.82
0.91
0.96
1.02
1.10
6.07
0.77
0.92
0.99
1.15
1.25
1.34
1.45
11.22
BTU/LB
15,355
15,156
14,999
14,625
14,378
14,206
14,074
10,768
15,355
15,170
15,022
14,748
14,567
14,434
14,312
11,687
15,355
15,211
15,095
14,901
14,764
14,657
14,559
12,484
15,355
15,1*7
15,001
14,636
14,394
14,224
14,093
10,836
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAK NUMBER 8
ORIGIN - JNIT NUMBE? <» L DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 18
SIZE FRACTION AND WEIGHT
1/3 BY 8M
PERCENT OF FLOW
50.8
8M BY 38.1
PERCENT OF FLOW
33.2
23M BY 103H
PERCENT OF FLOW
13.5
130M BY 335M
PERCENT OF FLOH
12.4
COMPOSITE
FL CURATE
11.2.3
SPECIFIC
SUAVITY
FLOAT-t. 30
1.30-1. 35
1.35-1 . fO
l.f 0-1. 50
1.50-1. 6C
1.60-1. 70
L. 70-1. 30
1.80-SIN<
FL3AT-1. 30
1.30-1. 55
1. 35-1. f 0
l.UO-l. 50
1.50-1. 60
1.60-1. 70
1. 70-1. 80
1.80-SINK
FL3AT-1. 30
1.30-1. 35
1. 35-1 . fO
l.f 0-1. 50
1.50-1.60
1.60-1-. 70
1.70-1.80
l.BO-5IN<
FL3AT-1. 30
1.30-1. 35
1.35-1.1.0
1. f 0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.10
1.8G-5IiMK
FL3AT-1. 30
1. 30-1. 35
1.35-1. <*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.93
1.93-SINK
HEIGHT
32.31
23.76
7.3if
8.26
3. 69
Z. 09
1.55
22.03
1*3.91
20 . 75
6.35
6.21
2. 87
1.72
1. 29
16.89
5f . 7 if
15.<*2
9. 09
5.09
2.fl
1 . 31
0.86
12. 07
fl.17
22.53
13. 30
5. 66
3.i*2
1.1<«
0 . 61*
12.65
39 . l
-------
USER HANDBOOK EXAMPLE PAGE 19
SUMMARY DF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 5
STREAM BLENDER
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
PROOL'CT
FEED 1
FEEO Z
ASH, PERCE
PROOICT.
FEEO 1..
FEED 2.
PYRITIC SULFJR, PER3ENT
PRODUCT
FEED i ,
FEEO a
TOTAL SULFUR,
PRODUCT. ..,
FEEO 1....,
FEEO 2
PERCENT
3TU/L3, MOISTURE FREE
PRODUCT
FEEO 1
FEED 2
12
BY
6
0.09
0.12
0.00
95. 01
95. 01
0. 00
0.39
0.89
0.00
0.97
0.97
O.OJ
727
727
0
6
BY
2
65.1*5
81*.3"*
0.00
39.25
39. 25
0.00
11. 06
11. 06
0.00
11.93
11.93
0. Ou
2
BY
1/2
32.79
15.1*9
92.73
27.02
27.02
27.02
1C.25
10.25
10.25
11.1*9
11.1*9
8,903 10,768
8,908 10,768
C 10,768
1/2
BY
SM
1.51
0.02
7.09
22.75
22.75
22.75
7.03
7.02
7.02
7.80
7.80
7.80
11,687
11,687
11,687
8H
BY
28M
0.03
3.00
0.12
17.93
17.93
17.93
5.<*a
5.1*2
5.1*2
6.07
6.07
6.07
13, ^Si*
12,1*81*
12,1*81*
28M
BY
100M
0.01
0. 00
O.Oi*
12.<*i»
12. 1*1*
12.1*1*
i*.06
i*.06
i*.C6
<».71
l*.71
i».71
13,217
13,217
13,217
100M
BY
325M
0.01
0.00
0.03
11.51*
11. 5<*
11. 5^
i*.31
<».31
<*.31
13,00'*
13,001*
13,00"*
COMP
100.00
100.00
100.00
35.02
37.1,3
26.70
10.71
10.91
10.01
11.71
11.85
11.22
9,555
9,185
10,836
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 9
ORIGIN - UNIT NUMBER 5 U DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 30
SIZE FRACTION A NO WEIGHT
12 BY 6
PERCENT OF FLOW
0. 1
6 BY 2
PERCENT OF FLOW
65.5
2 8Y 1/2
PERCENT OF FLOW
32.8
i/2 8Y 8M
PERCENT OF FLOW
1.6
COMPOSITE
FLOHRATE
296.3
SPECIFIC
GRAVITY
FLOftT-1. 30
1.30-1. 35
1.35-1. 40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1. 35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1 .35-1. 40
1 .1(0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. BO
1 ,80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1(0-1. 50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
1. 68
1.25
0.1*0
0. 70
0. 32
0. 19
0. 10
95.35
22. 29
11*. 09
3.5i(
11.23
2. 91
2. 07
0.97
1.2.90
25. 18
20. 15
6.51
9.97
i*. 6 if
2.55
1.57
29.1*3
32. 31
22.76
7.3i«
8. 26
3.68
2. 09
1.55
22. 03
23. 38
16.20
i».57
10.76
3.1*9
2.23
1.17
33.20
DIRECT, PERCENT
ASH PYRITIC
2.86
it. 61
9.12
16.01
26.3
-------
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 6
TWO-STAGE 9AUM JIG
SPECIFIC GRAVITY OF SEPARATION =1.63
USER HANDBOOK EXAMPLE PAGE Zl
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
FEED
CLEAN COAL
REFUSE
MIDDLINGS
12
8Y
6
0. 09
0.01
0.21
0.16
ASH, PERCENT
FEED 95. 01
CLEAN COAL 6.59
REFUSE 98.89
MIDDLINGS 98.25
PYRITIC SULFUR, PERCENT
FEED
CLEA N COAL
REFUSE
MIDDLINGS
TOTAL SLLFUR, PERCENT
FEED
CLEAN COAL
REFUSE
MIDDLINGS
BTU/L3, MOISTURE FREE
FEED
CLEAN COAL
REFUSE
MIDDLINGS
0.89
0.62
0.99
0.91
0.37
1.2«f
0.95
0.97
727
14,565
120
216
6
BY
2
65.1*5
59.06
75.36
70.31
39.25
6.65
71*.98
67.93
11.06
0.71
22.63
19.70
11.93
1.31*
23.76
20.77
8,908
14,522
2,765
3,945
2
BY
1/2
32.79
38.65
23.90
27.95
27. 02
3. 01
65.67
61.66
10.25
0.96
29.51*
26.52
11.1(9
1.56
32.12
28.86
10,768
14,290
3, 600
4,365
1/2
9Y
8M
1.61
2.21
O.t*8
1.50
22.75
9.53
72. 01
64.91
7.02
1.50
28.13
24.26
7.80
2.09
29.67
25. 64
11,687
14,033
2,961
'f,207
8M
BY
28M
0. 03
0. Of*
0. 00
0. 03
17. 93
9. 35
45. 85
68. 57
5.1.2
2. 05
16. 07
25.35
6. 07
2. 60
17. 02
26. 57
12,484
14,004
7,540
3,517
28M
BY
100M
0.01
0.01
0. 00
0.00
12. <*"•
8.1*5
50.1*0
60.i»Q
<*.06
2.17
21.69
26.81
2.76
22.89
28.17
13,217
14,055
5,271
3,150
100M
BY
325M
0.01
0.01
0.00
0.00
11.51*
7.1.9
1*8.13
57.79
I*.31
2.23
22.90
28.07
2.82
23.92
29.21
13,004
13,883
5,080
2,968
COMP
100.00
100.00
100.00
100.00
35.02
7.21*
72.80
66.19
10.71
0.82
21*.25
21.61.
11.71
1.1*1*
25.71.
23.06
9,555
14,421
2,958
4,059
-------
USER HANDBOOK EXAMPLE PAGE 23
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 6 (CONTINUED)
TWO-STAGE 3AUM JIG
SPECIFIC GRAVITY OF SEPARATION =1.62
SIZE, INCHES OR MESH
ASH ERROR 00
H FLOAT IN REFU3E PERCENT OF PRODUCT
TOTAL MISPLACED MATERIAL... PERCENT OF FEED
NEAR GRAVITY 0.1 MATERIAL.. UO
SPECIFIC GRAVITY OF SEPARATION
IMPERFECTION
EPRO°. AREA
DISTRIBUTION, PERCENT TO WASHED COAL
(SPECIFIC GRAVITY FRACTION)-
1. 30 -1.35
1. 35-1. (f 0
12
9Y
6
t. 7
<«.6
-------
USER HANDBOOK EXAMPLE PAGlI 23
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 10
ORIGIN - UNIT NUMBER 6 C DESTINATION - UNIT NUMBER
17
SIZE FRACTION AND HEIGHT
6 9Y 2
PERCENT OF FLOW
59.1
2 BY 1/2
PERCENT OF FLOW
38. 7
1/2 BY 8M
PERCENT OF FLOW
2.2
COMPOSITE
FLOHRATE
166.2
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1. 40
1. 1*0-1.50
1.50-1.60
1.60-1. 70
1.70-1. 80
1. BO-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 1*0
1.1.0-1.50
1.50-1.60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.i»0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.iiO
l.(»0-1.50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
HEIGHT
1*1*. 0<*
27. 81*
6.97
18.75
2.21
0.17
0. 03
0.00
38. 07
30. 1*1*
9. 80
li«.i»9
i*. 68
1.1*2
0.3i«
0.76
1*1.60
29. 11*
9.27
10. 00
3.77
1.68
0.91*
3.61
1*1.68
28.87
8.12
16.90
3.20
0.69
0.17
0.38
OIRECT,
ASH
2.83
«*.50
8.62
15.51*
25.78
32.75
1.2.99
0.00
2.62
'..61.
9.35
15.92
2.6.02
33. 81
<*3.01
69.61
2.1*7
I..75
9.59
15.75
25.82
33.75
1*1.92
75.21
2.75
i*.57
8.99
15.67
25.91
33.65
It2.87
70.80
, PERCENT
PYRITIC
SULFUR
0.15
0 . 6<*
1. 13
1.7<*
2.2<*
3.63
5. 76
0.00
0. 15
0.55
1.00
1.52
2.06
3.1*6
5.69
32.65
0.10
0.23
0.59
1.00
1.69
3. 03
i».39
30. Oi»
0.15
0.59
1.06
1.66
2.13
3.1*6
5.51*
32.07
TOTAL
SULFUR
0.80
1.31
1.73
2.33
2.77
l«.2l*
6.UO
0. 00
0.78
1.12
1.51
2. 08
2.52
3.93
6.21
35.1*8
0.67
0.81
1.07
1.53
2.10
3.36
(..66
31.67
0.79
1.22
1.61
2.2it
2.61
3.99
6.01.
31*. 63
BTU/LB
15,355
li*, 907
13,909
12,682
11,077
9,723
8,269
0
15,355
li«,907
13,909
12,682
11,077
9.723
6,269
2,81.1
15,355
11*, 907
13,909
12,682
11,077
9,723
6,269
2,397
15,355
li»,907
13,909
12,682
11,077
9,723
8,269
2»7<*2
HEIGHT
1*1*. 01*
71.87
78.81.
97.59
99.80
99.97
100.00
100.00
38.07
68.51
78.32
92.80
97.1.8
98.90
99.21*
100.00
1*1.60
70.73
80.00
90. 00
93.77
95.1*5
96.39
100.00
1*1.68
70.55
78.67
95.56
98.76
99.if5
99.62
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
2. 83
3.I.B
3.93
6.16
6.60
6.6<*
6.65
6.65
2.6?
3.52
l*.25
6.07
7.03
7.1.1
7.53
8.01
2.i»7
3.1*1
l*.13
5.1.2
6.21*
6.72
7.06
9.53
2.75
3.1.9
I*.06
6.11
6.75
6.9i»
7.00
0.15
0.3".
0.1*1
0.66
0.70
0.71
0.71
0.71
0.15
0.33
0.1*1
0.59
0.66
0.70
0.72
0.96
0.10
0.15
0.20
0.29
0.35
0.39
0.1*3
1.50
0.15
0.33
O.i*l
0.63
0.68
0.70
0.70
0.82
0.80
1.00
1.06
1.30
1.3U
1.31*
1.31.
0.78
0.93
1. 01
1.17
1.21*
1.28
1.29
1.56
0.67
0.73
0. 77
0.85
0.91
0.95
0.98
2.09
0. 79
0.97
1.03
1.25
1.29
1.31
1.32
1.1.1*
BTU/LB
15,355
15,181
15,069
li., 610
11., 532
li*, 521*
li*,522
li., 522
15,355
15,156
15,000
li., 638
li., i»67
li»,399
li*, 378
li«»290
15,355
15,170
15,021.
11., 761.
11., 616
li., 530
li», 033
15,355
15,172
15,01*1
11., 62*.
H*, 509
li*, 1*21
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 12
ORIGIN - UNIT NUMBER 6 R DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE
SIZE FRACTION AND HEIGHT
12 BY 6
PERCENT OF FLOW
0.2
6 BY 2
PERCENT OF FLOH
75.1.
2 BY 1/2
PERCENT OF FLOW
23.9
1/2 OY 8M
PERCENT OF FLOW
0.5
COMPOSITE
FLOHRATE
85.2
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1 .70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1. it 0-1. 50
1.50-1. 60
1 .60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. I'D
1.1*0-1. 50
1.50-1. 60
1 .60-1 . 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1. it 0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
0. 00
0. 00
0.00
0.10
0.10
0. 12
0.07
99.61
0. 00
0. 00
0. 00
2.61
2. 00
2.58
I.it6
91.36
0. 00
0. 09
0. 08
0.62
3. 21
3. 1.1
3. 29
89.30
0.20
0. 56
0.1.1
0. 21
1.1*8
1.90
2.25
92.99
0. 00
0. 03
0. 02
2.11
2.28
2.77
1.90
90.90
DIRECT, PERCENT
ASH PYRITIC
0.00
0.00
0.00
16.01
26.3U
33.93
1.1.. 1.7
99.1 6
0. 00
0.00
0.00
15.51*
25.78
32.75
1.2.99
79.1*5
0.00
l*.6i*
9.35
15.92
26.02
33.81
1*3. 01
69.61
2.1.7
(.. 75
9.59
15. 75
25.82
33.75
1.1.92
75.21
2.38
i*.65
9.37
15.56
25.86
33.07
<»2.99
77.18
SULFUR
0. 00
0. 00
0.00
1 .30
1.86
3. 12
5.91
0.89
0. 00
0 . 00
0.00
1 . 71*
2.21*
3.63
5. 76
2L. 1.7
0.00
0.55
1. 00
1.52
2.06
3.1.6
5.69
32.65
0.10
0.23
0.59
1.00
1.69
3. 03
I.. 39
10.01,
0.11
0.52
0.96
1.72
2.18
3.58
5.72
26.35
TOTAL
SULFUR
0, 00
0. 00
0.00
1. 82
2.33
3.69
6.1.5
0.91*
0. 00
0. 00
0. 00
2.33
2.77
l*.2t»
6.1*0
25.68
0. 00
1.12
1.51
2. 08
2.52
3.98
6.21
35.1*8
0.67
0.81
1. 07
1.53
2.10
3.36
1..66
31.67
0.68
1. 09
1.1*7
2.31
2.68
1..16
6.31
27.91,
BTU/LB
0
0
0
12,682
11,077
9,723
6,269
79
0
0
0
12,682
1 1,077
9,723
8,269
2,016
0
li«,907
13,909
1 2,682
11,077
9,723
8,269
2,81.1
15,355
1<»,907
13,909
12,682
11,077
9,723
8.269
2,397
1 5,355
11., 907
13,909
12,682
11,077
9,723
8,269
?,206
HEIGHT
0.00
0.00
0.00
0. 10
0.20
0.32
0.39
100.00
0.00
1. 00
0. 00
2.61
i*.60
7.18
8.6i*
100.00
0.00
0.09
0. 18
0.79
i*. 00
7.1.1
10. 70
100.00
0.20
0. 76
1. 17
1.38
2. 86
i*. 76
7.01
100.00
0. 00
0. 03
0. 05
2.16
'*.<*'.
7.21
9.10
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
0.00
0.00
0.00
16.01
21.31*
26.0!.
29.56
98.89
0.00
0.00
0. 00
15.51.
19.97
21..56
27.68
71..98
0.00
I*.61.
6.85
13.8 £
23.61
28.30
32.82
65.67
2.1.7
<».15
6.03
7.53
16.97
23.67
29.52
72.01
2.38
l*.55
6.73
15.37
20.75
25.48
29.13
72.80
0. 00
0.00
0.00
1.30
1.59
2.16
2.88
0.89
0.00
0.00
0. 00
,71.
,96
2.56
3.10
22.63
0.00
0.55
0.76
1.35
1.92
2.63
3.57
29.51.
0.10
0.19
0.33
0.'+3
08
86
1
1
2.67
28.13
0.11
0.50
0.71
1.70
1.95
2.57
3.23
k. 25
0.00
0.00
0.00
1.82
2. 09
2.69
3.1.0
0.95
0. 00
0. 00
0. 00
2.33
2.52
3.14
3.69
23.78
0.00
1.12
1.30
1.91
2.1*0
3.13
<«. 08
32.12
0.67
0. 77
0. 88
0.98
56
28
1.
2.
3. Oi*
29.67
0.68
1.07
1.25
2.29
2.1.9
3.13
3.80
ZS.Vt
BTU/LB
0
0
0
12,682
11,853
11,058
10,525
120
0
0
0
12,662
11,986
10,682
2,765
0
lit, 907
lit, 1*39
13,076
ll.i»7i»
10,668
9,931
3,600
15,355
15,026
li«,639
li*, 338
12,655
11,<.8«»
10,i*5lt
2,961
15,355
li., 927
lit, i. 66
12,722
11,878
11,051
10,1.71
2,958
-------
SPECIFIC GRAVITY ANALYSIS OF FLOHSTREAM NUMBER 11
ORIGIN - UNIT NUMBER 6 H DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 25
SIZE FRACTION AND HEIGHT
12 BY 6
PERCENT OF FLOW
0.2
6 BY 2
PERCENT OF FLOW
70. 3
CO
2 BY 1/2
PERCENT OF FLOW
28.0
1/2 BY 8M
PERCENT OF FLOW
1.5
JOMPCSITE
:LOHRATE
I.1..9
SPECIFIC
GRAVITY
FLOftT-1. 30
1.30-1. 35
1.35-1.1*0
l.i.Q-1. 50
1.50-1. 60
1.60-1. 70
1 .70-1. 80
1.80-SINK
FLCAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1.50-1.60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.i.Q
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
l.i.Q-1. 50
1.50-1.60
1.60-1. 70
1.70-1, 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.UO
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
HEIGHT
0. 00
0.00
0. 00
0.23
0.50
0.1*0
0.18
93. 70
0. 00
Q. 00
0. 05
5.1*0
6.96
6.9i»
2. 89
77.75
0.00
0. 01
0.12
2. 02
6. 76
6.97
5. 05
79.07
1.19
1.1*8
1. 01
3. 66
i».50
<*.<»7
<*. 1*1.
79.25
0. 0?
0. 02
0.09
i.. <*2
6. 85
6.90
3.52
78.18
DIRECT, PERCENT
ASH PYRITIC
0.00
0.00
9.12
16. 01
26.3i»
33.93
1*1*. i»7
99.16
0. 00
0.00
8.62
15.5i»
25. 78
32.75
<»2.99
79.i*5
0. 00
i*.6<»
9.35
15.92
26.02
33.81
4*3.01
69.61
2.i»7
i*.75
9.59
15.75
25. 82
33.75
M.92
75.21
2.(*7
i*. 75
9.08
15.59
25.81.
33. 06
1*2.98
76.65
SULFUR
0.00
0. 00
1.0
-------
SUMM4RY 3F THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 7
USER HANDBOOK EXAMPLE PAGE 2<
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
PRODUCT
FEED 1
FEED Z
18
BY
12
10.19
23.20
0. 05
STREAM BLENDER
12 6
BY BY
6 Z
33. 78
76. 8C
0.21
42.33
0.00
75.36
Z
BY
13.42
0.00
23.90
1/2
BY
8M
0.27
0.00
0. 46
8M
BY
28M
0. CO
O.CO
0.00
28M
BY
100M
c.oo
0.00
0.00
100M
BY
325M
O.CO
0. 00
0.00
COMP
100.00
100.00
100.00
ASH, PERCENT
PROOUCT . ..
FEED 1....
FEED 2....
PYRITIC SULFJR,
PRCOUCT
FEED i
FEED Z
TOTAL SULFUR, PERCENT
PRODUCT ,
FEEO i. ,
FEED z
97.73
97.73
99. 53
J. 43
0. 43
0.42
0. 46
0. 46
0.44
94.55
91*. 54
98. 89
0.97
0.97
0. 89
1.05
1.05
0.95
74.98
0.00
74.98
22.63
C.OO
22.63
23. 78
0.00
23. 73
65,67
0.00
65.67
29.54
0.00
29.5!»
32.12
0.00
32.12
72.01
O.GO
72.01
29.13
0.00
28.13
29.67
O.CO
29.67
45.85
0.00
45.85
16.C7
0.00
16.07
17.02
0.30
17.02
50.40
0.00
50.40
21.69
0.00
21.69
22.89
O.CO
22.89
48. 13
G. 00
48.13
22.90
0. 00
22.90
23.92
0. 00
23.92
82.65
95.28
72.80
13.99
0.84
24.25
14,36
0.92
25.74
BTU/L3, MOISTURE FR£E
PRODUCT
FEED 1.. ...i
FEED 2
332
333
54
793
795
12C
2,765
0
2, 765
3,633
0
3,600
2,961
0
2,961
7,540
0
7,540
5,271
0
5,271
5, 080
0
5,080
1,963
688
2 ,958
-------
USER HANDBOOK EXAMPLE PAGE 27
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAH NUMBER 13
ORIGIN - UNIT NUMBER 7 R DESTINATION - UNIT NUMBER
12
SIZE FRACTION AND HEIGHT
18 BY I?
PERCENT OF FLOW
10. 2
12 BY 6
PERCENT OF FLOW
33. 8
00
o
6 BY a
PERCENT OF FLOW
i»2.3
? BY 1/2
'ERCENT OF FLOW
13.
72 3Y 8M
'ERCENT OF FLOW
0.3
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-l.i«0
1.1*0-1.50
1.50-1. 60
1.60-1. 70
1.70-1. 60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 13 (CONTINUED*'
ORIGIN - UNIT NUMBER 7 R DESTINATION - UNIT NUMBER 12
USER HANDBOOK EXAMPLE PAGE 28
SIZE FRACTION AND WEIGHT
COMPOSITE
FLOHRATE
151.7
SPECIFIC
GRAVITY
FLOAT-1.30
1.30-1.35
1.35-1. 40
1.40-1.50
1.50-1.60
1.60-1.70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
HEIGHT ASH PYRITIC TOTAL
SULFUR SULFUR
BTU/LB
0.70
0.53
0.17
1.49
1.41
1.63
1.11
2.96
2.86
4.61
9.11
15.64
25.90
33.10
43.04
87.11
0.19
0.65
1.03
1.64
2.15
3.56
5.73
14.85
0.80
1.33
1.63
2,21
2.65
4.14
6.31
15.75
15,355
14,907
13,909
12,682
11,077
9,723
8,269
1,245
CUMULATIVE, PERCENT
HEIGHT ASH PYRITIC TOTAL
SULFUR SULFUR
BTU/LB
0.70
1.23
1.40
2.89
4.30
5.93
7. 04
100.00
2.86
3.61
4.29
10.13
15.30
20.20
23.80
82.65
0.19
0.39
0.47
1.07
1.42
2.01
2.60
13.99
0.80
1.02
1.10
1.67
1.99
2.58
3.17
14. 86
15,355
15,163
15,008
13,812
12,915
12,036
11,443
1,963
-------
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 8
SECONDARY MULTIPLE ROLL CRUSHER
CRUSHER SETTING = 0.28 INCHES
USER HANDBOOK EXAMPLE PAGE 29
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
ASH, PERCENT
PYRITIC SULFUR, PERCENT
TOTAL SLLFUR, PERCENT
BTU/LB, MOISTURE FREE
!••••• .. • 0
12
BY
6
• 16
• 00
• 25
• 00
• 91
• 00
. 97
.00
216
0
70.
0.
67.
0.
19.
0.
20.
o.
3,9
6
BY
2
3 1
0 0
<31
j ^
0 0
70
n n
u u
77
00
b5
0
27
o
61
o
26
0
28
o
b.
Z
BY
1/2
.95
.00
. 65
. nn
. u u
• 52
. 00
. 86
. 00
365
0
1/2
BY
8M
1.50
8. 67
fib. 41
U", . J i
cc p p
oo« c c
?d ? 6
c ^ . c o
71 ft1
b A. • O X
PC el.
£ 7 • O H
?T (M
C *3 . U O
4,207
<».057
8M
BY
28M
n. m
U . U >J
fib A1
o *, • o o
f>a. s?
o o . 7 r
cc p 7
DO . C O
pc •» c
C J . O y
?1 CQ
b X . V 7
pc c 7
c O. 7 r
91 n i
t O . U A
m 1 7
»* , y M. t
4.056
28H
BY
10QM
o.oo
1 Q A ?
1 7 • O C
t n i* n
D U • f U
fiA n 7
DO • u r
Pfi » A 1
C D • O i
5*1 7A
C 1 * f D
9A 1 7
C O • 1 r
0 » 99
C O « C C
•» . 4 c n
*J 9 &7 U
<..Q67
100M
BY
325M
0.00
6.68
57.79
66. 12
28. 07
71 .71
b X . f &
7Q.71
C J . C X
'7.1s;
c & . x ^
2<968
(..063
COMP
100 . 00
in Q . 00
^ U u . u u
66. 19
66. 19
21 . 6<»
a. fib
. O".
p» . n ft
C<3 . U u
?i . nfi
CiJ . U w
b, 059
If. 059
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 14
ORIGIN - UNIT NUMBER 8 M DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 30
SIZE FRACTION AND HEIGHT
1/2 BY 8M
PERCENT OF FLOW
8.7
8M BY 28M
PERCENT OF FLOW
64.8
00
LO
28M BY 1DOM
PERCENT OF FLOW
19. 8
10QM BY 325M
PERCENT OF FLOW
6.7
COMPOSITE
FLOWRATE
i* (..9
SPECIFIC
GRAVITY
FLOAT-1.30
1.30-1. 35
1.35-1. 40
l.i»0-1.50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 40
1.1*0-1.50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1. 35-1.1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1. 40
1.40-1. 50
1.50-1. 60
1.60-1.70
1.70-1.80
1.80-SINK
WEIGHT
0.03
0. 0<»
0. 09
<*. 1*1*
6.84
6. 88
3.51
78.18
0.02
0. 02
0. 09
4.44
6. 86
6.90
3.50
78.18
0. 02
0. 02
0. 09
4. 36
6. 85
6.90
3.56
78.21
0. 02
0. 03
0. 09
4. 39
6. 85
6.89
3.54
78.20
0.02
0. 02
0. 09
4.42
6.85
6.90
3.52
76.18
DIRECT, PERCENT
ASH PYRITIC
2.47
4.75
9. 12
15.59
25.81*
33. 06
42.97
76.71
2.47
4.75
9.07
15.59
25.84
33.05
42.98
76.71
2.47
4.75
9.08
15.59
25.85
33.08
42.98
76.46
2.47
4.72
9.04
15.59
25.84
33.07
42.98
76.54
2.47
4.75
9.08
15.59
25.84
33.06
42.98
76.65
SULFUR
0.10
0. 24
0.95
1.70
2.19
3.58
5.69
26.78
0 .10
0.25
0.99
1.70
2. 19
3.58
5.71
2 6s. 76
0.10
0.25
0.99
1 .70
2.19
3.58
5.71
26.97
0. 10
0.25
0.97
1. 70
2.19
3 .58
5.71
26.90
0. 10
0.25
0,98
1.70
2.19
3.58
5.71
26.81
TOTAL
SULFUR
0.67
0.82
1.49
2.28
2.69
4. 16
6.27
28.44
0.67
0.83
1.53
2.29
2.70
4.16
6.29
28.42
0.67
0.83
1.53
2.29
2.69
4.16
6.29
28.67
0.67
0.83
1.52
2.29
2.69
4.16
6.28
28.59
0.67
0.83
1.53
2.29
2.69
4.16
6.29
26.48
BTU/L8
15,355
14,907
13,909
12, 682
1 1,077
9,723
8.269
2,245
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2,245
15,355
14,907
13,909
12,682
1 1,077
9,723
8,269
2,266
15,355
14,907
13,909
12,682
11,077
9,723
8,269
2.259
15,355
14,907
13,909
12,682
11,077
9,723
6,269
2,250
WEIGHT
0.03
0. 07
0. 16
4.60
11.43
18. 31
21.82
100.00
0. 02
0. 04
0.12
4.57
11.42
18.32
21.82
100.00
0. 02
0. 04
0.12
4.48
11.34
18.24
21.79
100.00
0. 02
0. 04
0.13
4.52
11.37
18.26
21.80
100.00
0. 02
0. 04
0.13
4.55
11.40
18.30
21.62
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
2.47
3.76
6.92
15.29
21.60
25.90
28.64
66.22
2.47
3.77
7.39
15.36
21.65
25.94
28.68
66.23
2.47
3.78
7.45
15.37
21.70
26.01
28.78
66.07
2.47
3.77
7.29
15.35
21.67
25.97
28.73
66.12
2.47
3.77
7.35
15.36
21.66
25.96
28.70
66.19
0.10
0.18
0.63
1.66
1.98
2.58
3.08
21.61
0.10
0.18
0.73
1.68
1.99
2.59
3.09
21.59
0.10
0.19
0.74
1.67
1.98
2.59
3.10
21.76
0.10
0.18
0.71
1.67
1.98
2.58
3.09
21.71
0.10
0.18
0.72
1.68
1.98
2.58
3.09
21.64
0.67
0.76
1.19
2.25
2.51
3.13
3.64
23. 03
0.67
0. 76
1.29
2.26
2.52
3.14
3.65
23.01
0.67
0. 77
1.30
2.26
2.52
3.14
3.65
23.'22
0. 67
0. 76
1.27
2.26
2.52
3.14
3.65
23.15
0.67
0. 76
1.28
2.26
2.52
3.14
3.65
23.06
BTU/LB
15,355
15,102
14,398
12,741
11,746
10,987
10,550
4,057
15,355
15,098
14,286
12,726
11,736
10,978
10,543
4,056
15,355
15,097
14,274
12,726
11,729
10.970
10,529
4,067
15,?55
15,097
14,305
12,730
11,734
10,975
10,536
4,063
15,355
15,099
14,297
12,727
11,735
10,977
10,541
4,059
-------
USER HANDBOOK EXAMPLE PAGE 31
SUM14RY DF THE PERFORMANCE CHARACTERISTICS OF JNIT NUMBER 9
STREAM BLENDER
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
FEED 1
FEEO 2 ,
ASH, PERCENT
PRODUCT.
FEEO 2
PYRlTIC SULFJR, PERCENT
PR 0 0 UC T
TOTAL SULFUR, PERCENT
PRODUCT
FEEO ?-
BTU/L8, MOISTURE FREE
FEEO 2
1/2
BY
8M
'40.71
50.82
3.67
24.93
66.22
7.77
7.02
8.53
7.80
23.03
11,297
4,057
8M
BY
28M
33.21
23. 24
64.83
40. 54
17. 93
66.23
12.99
5. 42
21.59
14. 00
6.07
23. Cl
8,538
12, 484
4,056
28M
BY
100M
15.01
13.50
19.82
29.42
12. 44
66.07
9.67
4.06
21.76
10.57
4.71
23.22
10,320
13,217
4,067
100M
BY
325M
11.06
12.44
6.63
19.44
11 . 54
66.12
6.83
4.31
21.71
7.58
4.94
23.15
11,709
13,004
4,063
COMP
100.00
100.00
100.00
30.20
18. 85
65.19
9.68
5.91
21.64
10.57
6.63
23.06
10.280
12,243
4,059
-------
USER HANDBOOK EXAMPLE PAGE 3Z
SPECIFIC GRAVITY ANALYSIS OF FLOWSTPEAM NUMBER 15
ORIGIN - UNIT NUMBER 9 M DESTINATION - UNIT NUMBER
10
SIZE FRACTION AND WEIGHT
1/2 BY 8M
PERCENT OF FLOW
i*0. 7
8M BY Z8M
PERCENT OF FLOW
33. 2
00
Ul
23M BY 100M
PERCENT OF FLOW
15. 0
100M BY 325M
PERCENT OF FLOW
11. 1
COMPOSITE
FLOWRATE
187.1
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.<»0
1.1*0-1.50
1 .50-1. 60
1 .60-1 . 70
1.70-1. PO
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 30
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1 .70-1. 80
1 .80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.<40
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
30. 66
21 . 60
6. 97
8. 06
3. 81.
3.31.
1.65
2U. 90
23.36
11. 05
3.1.2
5. 38
i*. 71*
l». 15
2.32
l»5.58
37.1*1
10.51*
5.56
i*. 66
3. 82
3. 08
1.71
33.01
35. 21
19.27
11.81
5,1*8
3. 06
1.97
1. 06
22. 15
29.75
16. 18
6.11
6.1*0
it. 05
3.01
1.82
32.68
DIRECT, PERCENT
ASH PYRITIC
2.W
i«.75
9.58
15. 75
25.82
33.65
1*2. 03
75.1.5
1.95
i».i»l»
9.05
15.57
25.58
33.1i«
1*2.66
76.51
1.86
5.61
8.52
15.56
21*. 97
32.39
1.1.32
73.1*5
1.1*3
3. 21
it. 86
12.56
21.53
29.89
38.91*
69.53
2.08
i*.56
8.33
15.38
25.25
32.95
<»2.00
75.19
SULFUR
0. 10
0.23
0 .59
1.02
1.73
3. 11
1..53
29.52
0. 18
0 .1*1
0 .88
1.1*8
2. 11*
3.52
5.70
27.21*
0 .16
0.58
0.97
1 .72
2.1*2
3.68
5. 77
27,57
0 .12
0 .33
0 .1.9
1. 31
2.31.
3. 77
6.21.
28. 83
0. 13
0.32
0.67
1.25
2. 01.
3.1»i>
5.31
28.12
TOTAL
SULFUR
0.67
0.81
1. 07
1.56
2.16
3.1.8
i«. 81*
31.15
0.68
0.91*
1.38
2. 03
2.63
i*. 09
6.22
28.81.
0.72
1.10
1.1*5
2.29
2.90
k.27
6.35
29.21
0.66
0.83
1 . 07
1.81*
2.88
i*.2l«
6.82
30.28
0.68
0.88
1.18
1.80
2.51
3.91*
5.77
29.73
BTU/LB
15,355
1<*,907
13,909
12,682
11,077
9,723
8,269
2,373
15,355
lit, 907
13,909
12,682
11,077
9,723
8,269
2,250
15,355
I'M 907
13,909
12,682
11,077
9,723
8,269
2,271
15,355
H>, 907
1 3,909
12,682
1 1,077
9,723
8,269
2,11.5
15,355
li., 907
13,909
12.682
11,077
9,723
8,269
2,263
CUMULATIVE, PERCENT
WEIGHT ASH PYRITIC TOTAL
SULFUR SULFUR
BTU/LB
30. 66
52. 26
59. 22
67.28
71.12
73.1*6
75. 10
100.00
23. 36
3i». i»l
37.83
1*3.21
1,7.95
52.10
51*. 1*2
100.00
37.1*1
1*7.95
53.51
58, 38
62. 19
65.27
66.99
100.00
35.21
5i*. i*7
66.29
': 1 . 7 7
71*. 82
76.80
77.85
100.00
29.75
1*5.93
52. Qi*
58.1*5
62.1*9
65.50
67.32
100.00
2. **7
3.1*1
t.. li*
5.53
6.63
7.1*9
8.21*
2 it. 98
1.95
2.75
3.32
1..85
6.89
8.98
10.1*2
1*0.51.
1.86
2.6 "
3.29
t*.31
5.58
6.81*
7.73
29.1.2
1.1.3
2.06
2.56
3.32
i».07
-------
USER HANDBOOK EXAMPLE PAGE 3:
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 10
WET SINGLE DECK SCREEN
SIZE OF OPENING = 0.02 INCHES
SIZE, I NCHES OR MESH
SCREEN ANALYSIS. PERCENT-
FEED
ASH, PERCENT
FEED
PYRITIC SULFUR, PERCENT
FEEO
OVERFLOW (COARSE) STREAM
OTAL SULFUR, PERCENT
rU/L3, MOISTURE FREE
FEEO
IGHT RATIO, UNDERFLOW TO FEED.... PERCENT
OERSIZE MATERIAL IN OVERFLOW STREAM. DO
ERSIZE MATERIAL IN UNDERFLOW STREAM. DO
1/2
8Y
8M
<*0.71
i*1*. 98
0. 00
2«*.98
2«*. 98
0.00
7.77
7.77
0.00
8.58
8.58
0.00
11,297
11,297
0
0.0
0.0
0.0
0.0
8M
BY
28M
33.21
36.62
0.00
1*0.51*
1.0.51.
0.00
12.99
12.99
0.00
lit. 00
11*. 00
0.00
8,538
8,538
0
0.0
0.0
0.0
0.0
28M
BY
100N
15.01
12.26
1*1.86
29.1*2
29.1*2
29.1*2
9.67
9.67
9.67
10.57
10.57
10.57
10,320
10,320
10,320
25.9
25.9
12.3
0.0
•100 M
BY
325M
11.06
6.21*
58.K.
19.1.1*
19. <*i*
19.i»i*
6.83
"6.83
6.83
7.58
7.58
7.58
11,709
11,709
11,709
1*8.9
t*8.9
6.2
0.0
COMP
100. 00
100.00
100. 00
30. 20
30. 88
23. 62
9. 68
9.85
8. 02
10.57
10. 75
8. 83
10,280
10,193
11,128
9.3
10.1
18. 5
0.0
-------
USER HANDBOOK EXAMPLE PAGE
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 16
ORIGIN - UNIT NUMBER 10 U DESTINATION - UNIT NUMBER
11
SIZE FRACTION AND WEIGHT
1/2 BY 8M
PERCENT OF FLOW
44.9
8M BY 28M
PERCENT OF FLOH
36.6
28M BY 100M
PERCENT OF FLOW
12.3
100M 6Y 325M
PERCENT OF FLOW
6.2
COMPOSITE
FLOWRATE
169.7
SPECIFIC
GRAVITY
WEIGHT
DIRECT, PERCENT
ASH PYRITIC
SULFUR
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1. 40
.40-1. 50
.50-1. 60
.60-1. 70
.70-1. 80
.80-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1.40
.40-1. 50
.50-1. 60
.60-1. 70
.70-1.60
.80-51 NK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1.40
.40-1. 50
.50-1. 60
.60-1. 70
.70-1. 80
.80-SINK
FLCAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1.40
.40-1. 50
.50-1. 60
.60-1. 70
.70-1. 80
.80-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1.40
.40-1. 50
.50-1.60
.60-1. 70
.70-1. 80
.80-SINK
30.
21.
6.
8.
3.
2.
1.
24.
23.
11.
3.
5.
4.
4.
2.
45.
37
10.
5.
4.
3.
3.
1.
33.
35.
19.
11.
5.
3.
1.
1.
22.
29.
16.
5,
6.
4.
3.
1.
33.
66
60
97
06
84
34
65
90
36
05
42
38
74
15
32
58
41
54
56
66
82
08
71
01
21
27
81
48
06
97
06
15
10
23
80
53
12
07
87
29
2.
4.
9.
15.
25.
33.
42.
75.
1.
4.
9.
15.
25.
33.
42.
76.
1.
5.
8.
15.
24.
32.
41.
73.
1.
3.
4.
12.
21.
29.
38.
69.
2.
4.
8.
15.
25.
33.
42.
75.
47
75
58
75
82
65
03
45
95
44
05
57
58
14
66
51
86
61
52
56
97
39
32
45
43
21
86
56
53
89
94
53
14
63
74
51
42
09
13
49
0.
0.
0.
1.
1.
3.
4.
29.
0 .
0 .
0.
1 .
2.
3.
5.
27.
0.
0.
0.
1.
2.
3.
5.
27.
0.
0.
0.
1.
2,
3.
6.
28.
0.
0.
0.
1.
2.
3.
5.
28.
10
23
59
02
73
11
53
52
18
41
88
48
14
52
70
24
16
53
97
72
42
68
77
57
12
33
49
31
34
77
24
83
13
31
68
24
01
41
26
11
TOTAL
BTU/LB
SULFUR
0
0
1
1
2
3
4
31
0
0
1
2
2
4
6
28
0
1
1
2
2
4
6
29
0
0
1
1
2
4
6
30
0
0
1
1
2
3
5
29
.67
.81
. 07
.56
.16
.48
.84
.15
. 68
.94
.38
. 03
.63
.09
.22
.84
.72
.10
.45
.29
.90
.27
.35
.21
. 66
.68
.07
.64
.88
.24
.82
.28
.68
.87
.18
.78
.47
.91
.71
.72
15
14
13
12
11
9
8
2
15
14
13
12
11
9
8
2
15
14
13
12
1 1
9
8
2
15
14
13
12
11
9
6
2
15
,355
,907
,909
,682
,077
,723
,269
,373
,355
,907
,909
,682
,077
,723
,269
,250
,355
,907
,909
,682
,077
,723
,269
,271
,355
,907
,909
,682
,077
,723
,269
,145
,355
14,907
13
12
i 1
,909
,682
,077
9,723
8
,269
2,290
WEIGHT
30. 66
52.26
59.22
67.28
71.12
73.1.6
75.10
100.00
23.36
31..1*1
37. 83
1.3.21
1*7.95
52.10
5i*. i*2
100.00
37.1*1
1.7.95
53.51
58. 38
62.19
65. 27
66.99
100.00
35.21
51..i*7
66.29
71.77
71..82
76.80
77.85
100.00
29.10
45.33
51.13
57.66
61.77
61*.81*
66.71
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
2.1*7
3.1*1
4.14
5.53
6.63
7.1*9
8.2i*
21*.98
1.95
2.75
3.32
i*.85
6.89
8.98
10.1*2
<»0. 51*
1.86
2.66
3.29
4.31
5.58
6. Si*
7.73
29.1,2
1.1.3
2. 06
2.56
3.32
l». 07
4.73
5.19
19.1.1.
2.H.
3.03
3.68
5.02
6.38
7.61.
8.61
30.88
0.10
0.15
0.20
0.30
0.38
0.46
0.55
7.77
0.18
0.26
0.31
0.1.6
0.62
0.85
1.06
12.99
0.16
0.25
0.33
0.1.1*
0.56
0.71
0.81.
9.67
0.12
0.19
0.25
0.33
0.1*1
0.50
0.57
6.83
0.13
0.20
0.25
0.36
O.i*7
0.61
0.74
9.65
0.67
0.73
0. 77
0.86
0.93
,02
, 10
1.
1.
8.58
0. 68
0. 77
0.62
0.97
l.li*
1.37
1.58
li*. 00
0.72
0.80
0.87
0.99
1. 11
1.26
1.39
10.57
0.66
0. 7if
0. 80
0. 88
0.96
1. 05
1.12
7.58
0.68
0.75
0.80
0.91
1. 01
1.15
1.28
10.75
BTU/LB
15,355
15,170
15,022
14,741
11.,51*3
Ht, 390
14,256
11,297
15,355
15,211
15,093
Ht,793
11,,1.26
li»,052
13,805
8,538
15,355
15,257
15,117
li.,911*
14,676
li*,i.i»5
lis,287
10,320
15*355
15,197
li,,967
14,793
14,61*1
14,515
14,430
11,709
15,355
15,195
15,049
14,781
14,534
14,306
14,138
10,193
-------
USER HANDBOOK EXAMPLE PAGE 35
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAH NUMBER 17
ORIGIN - UNIT NUM3ER 10 I DESTINATION - UNIT NUMBER
13
SIZE FRACTION AND HEIGHT
28M BY 100M
PERCENT OF FLOW
1*1. 9
03
OO
100M BY 325M
PERCENT OF FLOW
58.1
COMPOSITE
FLOHRATE
17. i*
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.<»0-1. 50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
l.<»0-1.50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1. i*0
1.1*0-1. 50
1.50-1.60
1.60-1.70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
WEIGHT
37.i»l
10. 5i*
5.56
1*.86
3.82
3. 08
1.71
33. 01
35. 21
19.27
11. 81
5.1»8
3.06
1.97
1.06
22.15
36.13
15.61
9.20
5.22
3.38
2.<*i»
1.33
26. 70
ASH
1.86
5.61
8.52
15.56
2i*. 97
32.39
1*1.32
73.i»5
l.i«3
3.21
i*.36
12.56
21.53
29.89
38.91*
69.53
1.61
3.89
5.79
13.73
23.16
31.21
(*0.22
71.56
PYRITIC
SULFUR
0.16
0.58
0.97
1.72
2.«*2
3.68
5.77
27.57
0.12
0.33
0.1*9
1.31
2.3«*
3.77
6.2i»
28.83
O.li*
Q.i*0
0.61
l.<*7
2.39
3.73
5.99
28.18
TOTAL
SULFUR
Q. 72
1. 10
1.1.5
2.29
2.90
«*.27
6.35
29.21
0.66
0.83
1.07
1.81*
2.88
<*.2
-------
USER HANDBOOK EXAMPLE PAGE 36
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 11
CONCENTRATING TABLE
SPECIFIC GRAVITY OF SEPARATION =1.58
SIZE, INCHES OR MESH
if 2
3Y
8M
8M
BY
28M
Z8M
9Y
10 OH
100M
9Y
325M
COMP
SCREEN ANALYSIS, PERCENT-
FEED...... <.!.. H 8
CLEAN COAL • 51.31
REFUSE 31.. 9 7
g ASH, PEPCENT
^> FEED.
CLEAN COAL.
REFUSE
2<*.96
6.1.1
67. 02
36.62
27.37
50.89
-------
USER HANDBOOK EXAMPLE PAGE 37
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 11 (CONTINUED)
CONCENTRATING TABLE
SPECIFIC GRAVITY OF SEPARATION =1.58
SIZE, INCHES OR MESH
ACTUAL RECOVERY .................... PERCENT
THEORETICAL RECOVERY ............... DO
RECOVERY EFFICIENCY ................ DO
6TU RECOVERY ....................... DO
ASH ERROR .......................... DO
F'LOAT IN REFUSE ......... PERCENT OF PRODUCT
SINK IN CLEAN COAL ...... DO
TOTAL MISPLACED MATERIAL... PERCENT OF FEED
NEAR GRAVITY 0.1 MATERIAL.. 00
SPECIFIC GRAVITY OF SEPARATION .............
P3.03A3LE EPROR, SPECIFIC GRAVITY ...........
IMPERFECTION ...............................
ERROR AREA .................................
DISTRI3UTION, PERCENT TO WASHED COAL
(SPECIFIC GRAVITY FRACTIONI-
FLOAT-1.30 ...............................
1. 30-1. 35 .......... . .....................
1.35-1.40 ................................
1. 40 -1.50 ............ . .............. .....
1.50-1.60 ................................
1.60-1.70 ................................
1.70-1.80 ................................
SINK-1.80 ................................
1/2
BY
3M
69.1.
70.5
96. <•
89.6
0.3
5.1
2.2
3. 1
8. 8
1.55
0.015
100.0
99. 8
99.2
93. <.
55. 7
16.2
3.6
0.6
8M
BY
28M
i.5.«.
U6. i
gt.. 3
76.6
1. 3
it. 6
6. 1
5.3
9.6
1.51.
0.075
0.049
57
28M
BY
100M
63.0
67.7
93.1
86.8
2.3
11.8
<».6
7.3
5.3
1.68
0. 203
0. 121
118
99.5
98.8
95.5
79.8
«»6.1
19.5
7.5
1.0
98.1
96.2
93.1
85.3
71. 0
5<».7
38.1
5.6
100M
3Y
325M
83. 5
86. 1
97.1
95.8
1.6
33.5
6.2
10.7
5.5
2.02
0.256
0.127
168
99.1.
98.9
98.3
97.0
9<».l
88.5
76.1
33.1
COMP
60 .
63,
95.3
85.7
1.2
5.8
5.1
8.5
1. 56
0.066
0.01.2
66
99.5
99.2
97.5
86.7
55.2
35.«.
11.8
2.7
-------
USER HANDBOOK EXAMPLE PAGE 38
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 18
ORIGIN - UNIT NUMBER 11 C DESTINATION - UNIT NUMBER
16
SIZE FRACTION AND HEIGHT
1/2 BY RM
PERCENT OF FLOW 51.3
8M BY 28M
PERCENT OF FLOW
27.4
28M BY 100M
PERCENT OF FLOW
12.7
100M BY 325M
PERCENT OF FLOW
8.6
COMPOSITE
FLOWRATE
103.0
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1,35-1.140
1.1*0-1.50
1 .50-1 . 60
1.60-1. 70
1.70-1. 60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
l.«tO-1.50
1.50-1. 60
1.60-1. 70
1.70-1.80
1 .80-SINK
FLOAT-1. 30
1.30-1. 35
1 .35-1. 40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. <»0
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
44.20
31.07
9.96
10. 85
3. 08
0.51*
0. 09
0.22
51.26
21*. 06
7.20
9.47
i«. 82
1. 78
0.39
1. 03
58. 21
16. 08
8.21
6.58
4.30
2.67
1.03
2.91
41. 90
22. 82
13.90
6.36
3.1*5
2. 09
0.96
8.52
1*7.72
26. 53
9.32
9.5<»
3.7i»
1.29
0.36
1.50
DIRECT, PERCENT
ASH PYRITIC
SULFUR
2.1*7
i*. 75
9.58
15.75
25.82
33.65
(.2.03
75.1*5
1.95
i«.i«i*
9.05
15.57
25.58
33. 11*
1*2.66
76.51
1.86
5.61
8.52
15.56
2i*. 97
32.39
1*1.32
73.1*5
1.1*3
3.21
i*.86
12.56
21.53
29.89
38.94
69.53
2.14
4.63
8.75
15.50
25.27
32.60
1*1.25
72.26
0. 10
0.23
0.59
1 . 02
1. 73
3.11
it .53
29.52
0. 18
O.i»l
0.83
1.1*8
2. li*
3.52
5.70
27.21*
0 .16
0.53
0.97
1.72
2.1*2
3.69
5. 77
27.57
0.12
0.33
0.1*9
1.31
2.3i»
3. 77
6.21*
28.83
0 .13
0. 31
0 .6d
1.22
2. 02
3.51
5.71
28.37
TOTAL
SULFUR
0.67
0.81
1.07
1.56
2. 16
3.1*8
i*.8i»
31.15
0.68
0.91*
1.38
2.03
2.63
i*. 09
6.22
28.81.
0.72
1.10
l.<»5
2.29
2.90
4.27
6.35
29.21
0.66
0. 88
1. 07
1.81.
2. 88
i*.2i»
6.82
30.28
0.68
0.87
1. 18
1.77
2.i»9
4.03
6.2i«
29.81
8TU/LB
15,355
11*, 907
13,909
12,682
11,077
9,723
8,269
2,373
15,355
11*, 907
13,909
12,682
11,077
9,723
8,269
2,250
1 5.355
li*, 907
13,909
12,682
11,077
9,723
8,269
2,271
15,355
li*, 907
13,909
12,682
11,077
9,723
8,269
2,H*5
15,355
H., 907
13,909
12,682
11,077
9,723
8,269
2,213
HEIGHT
i»t*. 20
75.26
85.22
96. 07
99. 15
99.70
99.78
100.00
51.26
75.32
82.52
91.99
96.81
98.59
98.97
100.00
58.21
71..30
82.51
89. 09
93.39
96. 06
97. 09
100.00
1.1.90
61., 73
78.63
81..99
88.1.3
90.52
91.1*8
100.00
1.7. 72
71.. 25
83.57
93.11
96.85
98.11*
98.50
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL BTU/LB
SULFUR SULFUR
2.47
3.1*1
4.13
5.1*5
6.06
6.23
6.26
6.1*1
i;95
2.75
3.3 C
I*.56
5.61
6.10
6.25
6.97
1.86
2.67
3.25
4.16
5.12
5.8 B
6.26
8.2 1
1*3
06
2.55
3.30
I*.01
<*.61
i*.97
10.47
2.14
3.03
3.67
l*.6B
5.67
6.02
6.15
7.11.
0.10
0.15
0.20
0.29
0.3i*
0.35
0.36
0.42
0.18
0.25
0.31
0.43
0.52
0.57
0.59
0.86
0.1&
0.25
0.32
0.43
0.52
0.61
0.66
1.44
0.12
0.19
0.25
0.33
0.40
0.48
0.54
2.95
0.13
0.20
0.25
0.35
0.41
0,45
0.47
0.99
0.67
0.73
0.77
0.86
0.90
0.91
0.92
0.98
0.68
0.77
0.82
0.94
1.03
1. 08
1.10
1.39
0.72
0. 80
0.87
0.97
1.06
1.15
1.20
2.02
0.66
0. 74
0.80
0.88
0.96
1. 03
1.09
3.58
0.68
0.75
0.80
0.90
0.96
1.00
1.02
1.45
15,355
15,170
15,023
14,758
14,644
14,617
14,612
14,585
15,355
15,212
15,098
14,850
14,662
14,573
14,548
14,421
15,355
15,258
15,124
14,944
14 , 7 65
14,625
14,558
14,200
15,355
15,197
14,969
14,798
14,653
14,539
14,473
13,424
15,355
15,195
15,052
14,809
14,664
14,600
14,576
14,391
-------
USER HANDBOOK EXAMPLE PAGE 39
SPECIFIC GRflVITY ANALYSIS OF FLOWSTREAM NUMBER 19
ORIGIN - UNIT NUMBER 11 R DESTINATION - UNIT NUMBER
12
SIZE FRACTION AND HEIGHT
1/2 dY 8H
PERCENT OF FLOW
35. 0
8M BY 28M
PERCENT OF FLOW
50.9
28M BY 100M
PERCENT OF FLOW
11.5
100M BY 325M
PERCENT OF FLOW
2. 6
COMPOSITE
FLOHRATE
66.7
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1. 40
1.1(0-1.50
1 .50-1. 60
1.60-1. 70
1.70-1. 30
1. BO-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.1*0-1. 50
1.50-1. 60
1.60-1.70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1. 40
l.
-------
USER HANDBOOK EXAMPLE PAGE
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT
PRODUCT
FFEO 1 ........ .
FEED 2
ASH, PERCENT
PRODUCT.
FEED 1..
FEED 2,.
PYRITIC SULFUR, PERCENT
PRODUCT.. ...,..,
FEED 1.
FEED 2
TOTAL SULFUR, PERCENT
PRODUCT
FEED 1..
FEED 2
biTu/L3. MOISTURE FREE
PRODUCT............
FEED 1
FEED 2...
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 12
STREAM BLENDER
18
12
7- 08
10.19
0-00
97.73
97.73
0. 00
0.1*3
0.1.3
0.00
O.i»&
O.if6
0.00
332
332
0
12
BY
6
33.78
0. 00
9i».55
91,.55
0.00
0.97
0.97
0.00
1.05
1.05
0.00
793
793
0
6
BY
29.1*0
1,2.33
0. 00
71,.98
71* 99
0.00
22.63
22. 63
0. 00
23. 78
23. 78
0. 00
2,765
2,765
0
2
BY
1/2
9.32
0.00
65.67
65.67
0. 00
29.5<»
29.51,
0.00
32.12
32.12
0.00
3,600
3,600
0
1/2
BY
8M
10. 87
0. 27
31*. 97
67. 10
72. 01
67. 02
21*. 1*6
28. 13
25. 86
29. 67
25. 79
3,837
2,961
3,853
81
BY
28M
15.55
0.00
50.89
68.1,1
1,5.85
68.1*1
23. 06
16. 07
23.06
21,.i»7
17. 02
2i».l*7
3,655
7,51,0
3,655
28M
BY
1001
3.52
0.00
11.53
65.62
50.1,0
65.62
23.69
21.69
23.69
25.16
22.89
25.16
3,699
5,271
3,699
100M
BY
325M
0 .80
0. 00
2.61
61,. 95
«,8.13
61*.95
26.51
22.90
26.51
27.88
23.92
27.88
3,015
5, 060
3,015
COMP
100.00
100.00
100.00
78.03
82.65
67.51
16.95
13.99
23.69
17.99
11*. 86
25.10
2,1,98
1,963
3,713
-------
USE* HANDBOOK EXAMPLE PAGE «tl
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 20
ORIGIN - UNIT NUMBER 12 R ^ESTIMATION - UNIT NUMBER
II.
SIZE FRACTION AND HEIGHT
18 BY 13
PERCENT OF FLOW
7.1
12 BY 6
PERCENT OF FLOW
23.5
6 BY 2
PERCENT OF FLOW
29.1*
2 BY 1/2
PERCENT OF FLOW
9.3
1/2 BY 8M
PERCENT OF FLOW
10.9
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1.0-1. 50
1.50-1. 60
1.60-1.70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1.1.0
1.1,0-1.50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1. 35-1.1*0
1.1,0-1.50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1.0-1.50
1.50-1. 60
1.60-1. 70
1.70-1. BO
1.80-SINK
DIRECT, PERCENT
HEIGHT
0. 85
0.1.6
0. 09
0.1.9
0. 09
0. 08
0. 03
97. 89
1. 82
1.38
0.45
0. 73
0. 36
0.21
0.11
9i». 93
0. 00
0. 00
0. 00
2.61
2.00
2.58
1.1,6
91.36
0. 00
0. 09
0. 08
0.62
3.21
3.1.1
3. 29
89.30
0. 00
0.16
0.19
1.72
5.1,8
6.31
5.13
80.99
ASH
2.80
1..1.0
7.80
15.1,0
25. 00
31.50
1,1. 00
99.65
2.87
l».63
9.17
16.03
26.39
3i». 09
<*i*.65
99.08
0.00
0.00
0. 00
15.51,
25.78
32.75
t.2.99
79.<*5
0.00
<«.6t<
9.35
15.92
26.02
33.81
1,3.01
69.61
2.1*7
it.75
9.58
15.75
25.82
33.65
1,2.03
75.l»5
PYRITIC
SULFUR
0.21
0.71
0.93
1.10
1.1,1,
2.90
5.1*6
0.1,2
0.19
0.61*
l.Oi.
1.32
1.87
3.H*
5.93
0.97
0.00
0.00
0.00
1.71.
2.21.
3.63
5.76
21.. i*7
0.00
0.55
1. 00
1.52
2.06
3.1*6
5.69
32.65
0.10
0.23
0.59
1.02
1.73
3.11
i».53
29.53
TOTAL
SULFUR
0. 79
1.57
1.59
1.60
1.81*
3.50
6.13
O.i«i*
0.60
1.31
1.61*
1.65
2.36
3.70
6.1*6
1.03
0. 00
0.00
0. 00
2.33
2.77
i».2i»
6.1*0
25.68
0. 00
1.12
1.51
2. 08
2.52
3.98
6.21
35.1*8
0.67
0.81
1.07
1.56
2.16
3.1*8
i».83
31.16
BTU/L8
15,355
li*, 907
13,909
12,682
11,077
9,723
8,269
35
15,355
li«,907
13,909
12,682
11,077
9,723
8,269
67
0
0
0
12,682
11,077
9,723
6,269
2,016
0
li*,907
13,909
12,682
11,077
9,723
8,269
2,81.1
15,355
11*, 907
13,909
12,682
11,077
9*723
8,269
2,373
HEIGHT
0.85
1.33
1.1*2
1.91
2.00
2.08
2.11
100.00
1.82
3.20
3.61*
1..38
i*.7i»
i*.95
5. 07
100.00
0.00
0.00
0. 09
2.61
i*.60
7.18
8.61*
100.00
0. 00
0.09
0.18
0.79
i*. 00
7.1*1
10.70
100.00
0. 00
0.17
0.36
2.08
7.57
13.83
19.01
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
2.80
3.37
3.66
6.67
7.50
8.1*5
8.96
97.73
2.87
3.62
l*.31
6.28
7.82
8.91*
9.73
91*.55
0.00
0. 00
0.00
15.5i»
19.97
21*.56
27.68
71*.98
0.00
<«.6t»
6.85
13.6S
23.61
28.30
32.82
65.67
2.«*7
if. 71
7.33
II*. 28
22.65
27.65
31.53
67.10
0.21
0.39
0.1*3
0.60
0.6
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 20 (CONTINUED)
ORIGIN - UNIT NUMBER 12 R DESTINATION - UNIT NUMBER l
-------
USER HANDBOOK EXAMPLE PAGE <»3
SIZE, I M3HES OR MESH
.SUMMARY DF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 13
FROTH FLOTATION CELL
28M
BY
100M
100M
BY
325M
COMP
SCREEN ANALYSIS, PE3CENT-
FEEO 1.1.86 59.1<4 100.00
CLEAN COAL 37.05 63.95 100.00
REFUSE 51.09 1.8.91 100.00
ASH, PERCENT
g FEED 29.1,2 19.<.i» 23.62
en CLEAN COAL 5.62 <». 15 U.70
REFUSE 52.56 57.22 59.95
PYRITTC SULFJR, PERCENT
FEEO 9.67 6.63 8.02
CLEAN COAL ' C. 78 0.56 0.6<»
REFUSE, 22.0i« 22.32 22.18
TOTAL SULFUR, PERCENT
FEED 10.57 7.58 8.83
CLEAN COAL 1.33 1.12 1.20
REFUSE 23.1*3 23.55 23.1,9
BTU/L3, MOISTURE FRE£
FEEO 10,320 11,709 11,126
CLEAN COAL 1<»,678 1<*,6<»2 1<»,655
REFUSE i>,252 <»,<«63 4,355
-------
USER HANDBOOK EXAMPLE PAGE
SIZE, INCHES OR MESH
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 13 (CONTINUED)
FROTH FLOTATION CELL
2«M
100M
ACTUAL RECOVERY PERCENT
DO
DO
DO
00
PRODUCT
THEORETICAL RECOVERY
RECOVERY EFFICIENCY ,.
BTU RECOVERY.. . . .
ASH ERR CR
FLOAT IN REFUSE.... PERCENT OF
SINK IN CLEAN COAL DO
TOTAL MISPLACED MATERIAL... PERCENT OF FEED
NEAP GRAVITY 0.1 MATERIAL.. DO
SPECIFIC GRAVITY OF SEPARATION
PP.03A9LE ERROR, SPECIFIC GRAVITY
I '-1 P£ R FE C T10 N . . . .
ERROR AREA
DISTRIBUTION, PERCENT TO WASHED COAL
(SPECIFIC GRAVITY FRACTIONI-
FLOAT-1.30
1.30-1.39....
1. 35-l.(*3.
1.1*0-1.50.
1.50-1.60=
1.60-1.70.
1.70-1.80.
SINK-1.80.
58.2
62.3
93. <»
82 . 8
!.*»
8. 0
it.6
6. 0
8.4
1.51
0.086
0.057
70
98.6
96. 1
89. 0
69.4
39.9
19.3
10.5
1.8
100M
BY
325M
71.2
75.1
9
-------
USER HANDBOOK EXAMPLE PAGE <*5
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 21
ORIGIN - UNIT NUMBER 13 C DESTINATION - UNIT NUMBER
16
SIZE FRACTION AND WEIGHT
28M 8Y lOOM
PERCENT OF FLOH 37.1
100M BY 325M
PERCENT OF FLOH 62.9
COMPOSITE
FLOHRATE
11
SPECIFIC
GRAVITY
FLOAT-1.30
1.30-1.35
1.35-1.1*0
1.1*0-1. 50
1.50-1. 60
1.60-1.70
1.70-1. 80
1.80-SINK
FLOAT-1.30
1.30-1. 35
1.35-1.<*0
1.1*0-1.50
1.50-1.60
1.60-1. 70
1.70-1.60
1.80-SINK
FLOAT-1.30
1.30-1. 35
1.35-1.1*0
1.1*0-1.50
1.50-1.60
1.60-1.70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
HEIGHT
63. 37
17.1.0
8.50
5. 80
2.62
1. 02
0.31
0.99
i»9. 05
26. 35
15.37
5.82
1.97
0.61.
9. 18
0.61.
5<».35
23. 03
12.82
5.81
2. 21
0.78
0.23
0.77
ASH
1.86
5.61
8.52
15.56
21*. 97
32.39
1*1. 3£
73.1*5
1.1.3
3.21
l».86
12.56
21.53
29.89
38.91*
69.53
1.61
3.88
5. 76
13.67
23.Q1*
31.10
<»0.1<»
71.«*1
PYRITIC
SULFUR
0.16
0.58
0.97
1.72
2.1*2
3.68
5.77
27.57
0.12
0. 33
0.1*9
1.31
2.3<»
3.77
6.21*
28.83
O.li*
0.1*0
0.61
1.1*6
2.38
3.73
6.01
28.23
TOTAL
SULFUR
0.72
1.10
1.1.5
2.29
2.90
i*.27
6.35
29.21
0.66
0.88
1.07
1.84
2.88
«».2«*
6.82
30.28
0.69
o.9<»
1.16
2.01
2.89
i*.25
6.58
29.77
BTU/LB
15,355
li»,907
13,909
12,682
11,077
9,723
8,269
2,271
15,355
li«,907
13,909
12,682
11,077
9,723
8,269
2,11*5
15,355
1<»,907
13,909
12,682
11,077
9,723
8,269
2,205
WEIGHT
63.37
80.77
89.26
95.06
97.68
98.70
99.01
100.00
1*9.05
75.39
90.76
96.57
98.51*
99. 19
99.36
100.00
5i*.35
77.38
90.20.
96.01
98.22
99.00
99.23
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
1.86
2.67
3.22
3.9fc
i*.51.
<*.83
«*.9i*
5.62
l.(*3
2.05
2.53
3.13
3.50
3.67
3.73
i*.15
1.61
2.29
2.78
3.1*1.
3.88
1..10
(..18
if.70
0.16
0.25
0.32
0.1*0
0.1*6
O.i«9
0.51
0.78
0.12
0.19
0.21*
0.31
0.35
0.37
0.38
0.56
O.li.
0.22
0.27
0.31*
0.39
0.1*2
0.1*3
0.61*
0. 72
0. 80
0.86
0.95
1. 00
1. 0«*
1. 05
1. 33
0.66
0.71.
0.80
0.86
0.90
0.92
0.93
1.12
0.69
0.76
0.82
0.89
0.91*
0.96
0.98
1.20
BTU/LB
15,355
15,258
15,130
1<*,981
1<*,676
lit,823
I'M 802
H*,678
15,355
15,198
11*,980
lit,81,2
11,,767
li»,73i»
li»,722
li.,6<*2
15,355
15,222
15,035
11*,893
11*,807
11*,767
1«*,752
H.,655
-------
USER HANDBOOK EXAMPLE PAGE 46
SPECIFIC GRAVITY ANALYSIS OF FLOHSTREAM NUMBER 22
ORIGIN - UNIT NUM8EK 13 R DESTINATION - UNIT NUMBER
14
SIZE FRACTION AND WEIGHT
28M BY 100M
PERCENT OF FLOW 51.1
100M BY 325M
PERCENT OF FLOW 48.9
COMPOSITE
FLOHRATE
6.0
SPECIFIC
GRAVITY
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1.35
.35-1.40
.40-1.50
.50-1. 60
.60-1. 70
.70-1.80
.80-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1. 40
.40-1. 50
.50-1. 60
.60-1. 70
.70-1. 80
.80-SINK
FLOAT-1. 30
1
1
1
1
1
1
1
.30-1. 35
.35-1.40
.40-1. 50
.50-1.60
.60-1.70
.70-1.80
.80-SINK
HEIGHT
1. 28
0.
1.
3.
5.
5.
3.
77.
1.
1.
6,
4.
5.
5.
3.
75.
1.
1.
2.
t,.
5.
5.
3.
76.
99
47
56
49
95
67
59
02
78
04
64
75
26
23
29
15
38
24
09
62
61
45
46
DIRECT, PERCENT
ASH PYRITIC
SULFUR
1.86 0. 16
5.
8.
15.
24.
38.
41.
73.
1.
3.
4.
12.
21.
29.
38.
69.
1.
4.
6.
13.
23.
31.
40.
71.
61
52
56
97
39
32
45
43
21
86
56
53
89
94
53
67
09
09
90
25
25
23
56
0.
0.
1.
2 .
3.
5.
27.
a-.
0 .
0 .
1.
2.
3.
6.
28.
0.
0.
0.
1.
2.
3.
5.
28.
58
97
72
42
68
77
57
12
33
49
31
34
77
24
83
14
42
65
49
38
73
99
18
TOTAL
SULFUR
0.72
1.
1.
2.
2.
4.
6.
29.
0.
0.
1.
1.
2.
4.
6.
30.
0.
0.
1.
2.
2.
4.
6.
29.
10
45
29
90
27
35
21
66
68
07
84
88
24
82
28
70
96
20
04
89
25
57
73
BTU/LB
15,355
14,907
13,
12,
1 1,
9.
8,
2,
15,
14,
13,
12,
11,
9,
8,
2,
15,
14,
13,
12,
909
682
077
723
269
271
355
907
909
682
077
723
269
145
355
907
909
682
11,077
9,
723
8,269
2,210
WEIGHT
1.28
2.27
3.71,
7. 30
12.79
18.71,
22.1,1
100.00
1. 02
2.80
5.81,
10.1,8
16.23
21.1,8
21,. 71
100.00
1.15
2.53
i».77
8.95
Ii».
-------
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 14
STREAM BLENDER
USER HANDBOOK EXAMPLE PAGE 47
SIZE, INCHES OR MESH
18
8Y
12
12
BY
6
6
BY
2
2
BY
1/2
1/2
BY
8M
8M
BY
28M
28M
BY
100M
100M
BY
325H
COMP
SCREEN ANALYSIS, PERCENT-
PRODUCT
FEED 1
FEED 2
6.99
7.08
0.00
22.83
23.46
0.00
28.62
29.UO
0.00
9.07
9.32
0.00
10.58
10. 87
0. 00
15.14
15.55
0.00
4.78
3.52
51.09
2.08
0.80
48.91
100.00
100.00
100.00
ASH, PERCENT
PRODUCT 97.73
FEED 1 97.73
FEED 2.
o
o
PYRiriC SULFUR, PERCENT
PRODUCT ,
FEED 1
FEED 2
0.00
0.
-------
USER HANDBOOK EXAMPLE PAGE «»8
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAH NUMBER 23
ORIGIN - UNIT NUMBER 14 R DESTINATION - UNIT NUMBER
15
SIZE FRACTION AND HEIGHT
18 8Y 12
PERCENT OF FLOW
6.9
12 BY 6
PERCENT OF FLOW
22. 8
6 BY 2
PERCENT OF FLOW
28. 6
2 3Y 1/2
PERCENT OF FLOW
9.1
1/2 BY 8M
PERCENT OF FLOW
10. 6
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-l.f 0
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 75
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.4 0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1.50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
0. 85
0.
0.
0.
0.
0.
0.
97.
1.
1.
0.
0.
0.
0.
0.
94.
0.
0.
0.
2.
2.
2.
1.
91.
0.
0.
0.
0.
3.
3.
3.
89.
0.
0.
0.
1.
5.
6.
5.
80.
48
09
49
09
08
03
8S
82
38
45
73
36
21
11
93
00
00
00
61
00
58
46
36
00
09
08
62
21
41
29
30
00
16
19
72
48
31
13
99
DIRECT, PERCENT
ASH PYRITIC
SULFUR
2.80 0.21
4.
7.
15.
25.
31.
41.
99.
2.
4.
9.
16.
26.
34.
44.
99.
0.
0.
0.
15.
25.
32.
42.
79.
0.
4.
9.
15.
26.
33.
43.
69.
2.
4.
9.
15.
25.
33.
42.
75.
40
80
40
00
50
00
65
87
63
17
08
39
09
65
08
00
00
00
54
78
75
99
45
00
64
35
92
02
31
01
61
47
75
58
75
82
65
03
45
0
0
1
1
2
5
0
0
0
1
1
1
3
5
0
0
0
0
1
2
3
5
24
0
0
1
1
2
3
5
32
0
0
0
1
1
3
4
29
. 71
.98
.10
.44
.90
.46
.42
.19
. 64
. 04
.32
.87
.14
.93
.97
. 00
. 00
.00
. 74
.24
.63
.76
.47
.00
.55
. 00
.52
. 06
.46
.69
.65
.10
.23
.59
.02
.73
.11
.53
.53
TOTAL
SULFUR
0.79
1
1
1
1
3
6
0
0
1
1
1
2
3
6
1
0
0
0
2
2
4
6
25
0
1
1
2
2
3
6
35
0
0
1
1
2
3
4
31
.57
.59
.60
.84
.50
.13
.44
.80
.31
.64
.85
.36
. 70
.46
. 03
. 00
. 00
.00
.33
. 77
.24
.40
.68
. 00
.12
.51
. 08
.52
.98
.21
.48
.67
.81
. 07
.56
.16
.48
,83
.16
BTU/LB
1 5,355
14,907
13,909
12,682
11,077
9,723
8,269
35
15,355
14,907
13,909
12,682
11,077
9.723
8,269
67
0
0
0
12,682
11,077
9,723
8,269
2,016
0
14,907
13,909
12,682
11,077
9,723
8,269
2,841
15,355
14,907
13,909
12,682
11,077
9,723
6,269
2,373
HEIGHT
0.85
1.33
1.42
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL
SULFUR SULFUR
91
00
08
2.11
100.00
1. 82
3.20
3.64
4. 38
4. 74
4.95
5.07
100.00
0. 00
0.00
0.00
2. 61
4.60
7.18
8. 64
100.00
0. 00
0.09
0.18
0. 79
4. 00
7.41
10.70
100.00
0.00
0.17
0. 36
2. 08
7.57
13.88
19.01
100.00
,80
,37
,66
6.67
7.50
6.45
8.98
97.73
2.87
3.62
4.31
6.28
7.82
8.94
9.73
94.55
0.00
0.00
0.00
15.54
19.97
24.56
27.68
74.98
0.00
4.64
6.85
13.8 3
23.61
28.30
32.82
65.67
2.47
4. 71
7.33
14.28
22.65
27.65
31.53
67.10
0.21
0.39
0.43
0.60
0.64
0.73
0.80
0.43
0.19
0.38
0.47
0.61
0.71
0.81
0.92
0.97
0.00
0.00
0.00
1.74
1.96
2.56
3.10
22.63
0.00
0.55
0.76
1.35
1.92
2.63
3.57
29.54
0.10
0.22
0.42
0.91
1.51
2.24
3.86
24.46
0.79
1.07
,10
,23
,26
,35
,43
0.46
0. 60
1.02
1. 09
1. 22
1.31
1.41
1.52
1.05
0.00
0. 00
0. 00
2.33
2.52
3.14
3.69
23. 78
0. 00
1. 12
1.30
1.91
,40
, 13
, 08
2.
3,
4.
32.12
0.67
0. 81
0.95
1.45
1.96
2.65
3.24
25.86
BTU/LB
15,355
15,194
15,112
14,489
14,334
14,152
14,055
332
15,355
15,162
15,008
14,618
14,347
14,150
14,020
793
0
0
0
12,682
11,986
11,174
10,632
2,765
0
14,907
14,439
13,076
11,474
10,668
9,931
3,600
15,355
14,916
14,376
12,976
11,599
10,746
10,078
3,837
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 23 (CONTINUED)
ORIGIN - UNIT NUMBER l
-------
USEft HANDBOOK EXAMPLE PAGE 50
SUMMARY OF THE PRE-8REAKAGE PERFORMANCE OF UNIT NUMBER
CEMTRIFUGf
15
ho
o
CO
SIZE, INCHES OR MESH
SCFEEN ANALYSIS, PERCENT-
ASH, PERCENT
PYRITIC SULFUR, PERCENT
TOTAL SULFUR, PERCENT
BTU/LB, MOISTURE FREE
18
3Y
12
A Q
« ( J
• 53
. 73
. 73
.43
.1,3
.<» 6
,46
332
332
12
6Y
6
? ? fl ^
c £ • O J
11,82
94.55
95. o j
0.97
0.89
1.05
0.97
793
rzt>
6
QY
2
? R ft?
c O • OC
21* . 81*
71,. 98
82.40
22. 63
l
-------
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 15
CENTRIFUGE
UPPER FLOH STREAM = 99.0 PERCENT OF FEED
USER HANDBOOK EXAMPLE PAGE 51
SIZEt INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
FEED
PRODUCT 1 (U^PER STREAM)
PRODUCT 2 (LOWER STREAM!
ASH, PERCENT
ho FEED
o
PRODUCT 1 (UPPER STREAM! 97.73
PRODUCT 2 (LOWER STREAM! ,
PYRITIC SULFUR, PERCENT
FEED
PRODUCT 1 (UPPER STREAM).
PRODUCT ? (LOWER STREAM),
TOTAL SULFUR, PERCENT
FEED
PRODUCT 1 (UPPER STREAM!.
PRODUCT 2 (LOWER STREAM).
BTU/L3, MOISTURE FREE
FEED
PRODUCT 1 (UPPER STREAM),
PRODUCT Z (LOWER STREAM),
18
BY
12
6.89
2.53
2.53
7.73
7.73
7.73
0.43
0.46
0.46
0.46
332
332
332
12
BY
6
22.83
11.82
11.82
94.55
95.02
95.02
0.97
0.89
0.89
1.05
0.97
0.97
793
724
724
6
BY
2
28.62
24.84
74.98
82.40
82.40
22.63
14.60
14.60
23.78
15.36
15.36
2,765
2,007
2,007
2
BY
1/2
9.07
19.25
19.25
65.67
76.99
76.99
29.54
19.52
19.52
32.12
20.84
20.84
3,600
2,527
2,527
1/2
BY
8M
10. 58
14. 75
14.75
67. 10
71. 08
71. 08
24.46
22. 83
22. 83
25.86
24.27
24. 27
3,837
3,281
3,281
8M
BY
28M
15.14
15.41
68.41
68.78
68.78
23.06
23.13
23.13
24.47
24.55
24.55
3,655
3,601
3,601
28M
BY
100M
4.78
7.74
7.74
64.75
66.47
66.47
23.22
23.21
23.21
24.67
24.65
24.65
3,856
3,745
3,745
100M
BY
325M
2.08
3.66
3.66
60.11
63.50
63.50
23.89
23.59
23.59
25.17
24.93
24.93
3,921
3,806
3,806
CONP
10 0.00
100.00
100.00
77.55
77.55
77.55
17.09
17.09
17.09
18.14
18.14
18.14
2,547
2,547
2,547
-------
SPECIFIC GRAVITY ANALYSIS OF FLOHSTREAM NUMBER 24
ORIGIN - JNIT NUMBER 15 U DESTINATION - UNIT NUMBER
USE'* HANDBOOK EXAMPLE PAGE 5Z
SUE FRACTION AND WEIGHT
18 BY 13
PERCENT OF FLOW
2.5
12 BY 6
PERCENT OF FLOW
11.8
ho
o
Ln
6 BY 2
PERCENT OF FLOW
24.8
Z BY 1/2
PERCENT OF FLOW
19.3
BY 8,1
PERCENT OF FLOW
14.7
SPECIFIC
SRAVIfY
FLDAT-l. 30
1.30-1.35
1.35-1.40
1.40-1. 50
1.50-1. 60
U60-U 70
1.70-U 30
1. SB-SINK
FLDftT-1. 30
1.30-1. 35
1. 35-1. 40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-3INK
FLOAT-U 30
1.30-1.35
1.35-1. 40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 30
USD-SINK
a
FLDAT-U 30
U30-U 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 30
USD-SINK
FL3AT-1 . 30
1.30-U 35
1.35-1.40
1.40-U 50
1.50-U 60
1.60-t. 70
U70-U80
USO-SINK
HEIGHT
0.85
0.48
0.09
0.49
0.09
0.03
0.03
97.89
1.63
1.24
0.40
0.70
0.32
0.19
0.10
95.37
0.61
0.45
0.14
1. 90
1. 38
1.70
0 .96
92.87
0.39
0 . 32
0.12
1.57
1.95
2.26
1.68
91.71
0.16
0.22
0.15
1.61
3.86
4.43
3.55
66.02
DIRECT, PEf!
ASH PYR]
2.80
4.40
7. 80
15.40
25. 00
31.50
41.00
99.65
2.86
4.61
9.12
16. 01
26.34
33.93
44.47
99.16
2.86
4.61
9.11
15.60
25.82
32.80
43.05
86.93
2.86
4.61
9. 17
15.63
25.91
33.24
43.02
81.48
2.86
4.67
9 = 45
15.70
25,85
33.56
42.29
77.66
sin
t
<
t
1
i
?
s
t
0
0
1
J
1
3
5
C
6
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 2 4 (CONTINUED)
ORIGIN - UNIT NUMOER 15 U DESTINATION - UNIT NUMBER 0
USER HANDBOOK EXAMPLE PAGE 53
SIZE FRACTION AND WEIGHT
8M BY 28M
PERCENT OF FLOW
15.
28M BY 100M
PERCENT OF FLOW
7.7
100M BY 325M
PERCENT OF FLOW
3. 7
COMPOSITE
FLOW RATE
222.2
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 1.0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
ELOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1.50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.<*0-1. 50
1.50-1.60
1.60-1.70
1.70-1.80
1.80-SINK
CIRF.CT, PERCENT
WEIGHT
0. 19
0. 2i*
0.26
1.91
if. 57
5.82
3.93
83.10
1. 08
0.71
0. 77
2.18
it. 07
4.97
3.1*6
82.76
0.81*
1. 07
1. 53
2.72
4.16
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 25
ORIGIN - UNIT NUMBER 15 L DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE
SIZE FRACTION AND HEIGHT
18 BY 12
PERCENT OF FLOW
2.5
13 BY 6
PERCENT OF FLOW
11.8
6 QY 2
PERCENT OF FLOW
21*.8
2 BY 1/2
PERCENT OF FLOW
19. 3
1/2 BY 8M
PERCENT OF FLOW
*. 7
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1 .50-1 . 60
1.60-1. 70
1.70-1. 60
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-l.i»0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1 .30-1. 35
1.35-1. i»0
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.60
1.80-SINK
FLOAT-1 . 30
1.30-1. 35
1.35-1.1*0
1.1*0-1.50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
HEIGHT
0. 85
0.<*8
0. 09
0.1*9
0. 09
0. 08
0.03
97.89
1. 68
1.2i*
0.1.0
0. 70
0. 32
0.19
0. 10
95. 37
0.61
n. i«5
0. li*
1.90
1.38
1. 70
0.96
92.67
0.39
0. 32
0, 12
1.57
1.95
2. 26
1.68
91.71
0. 16
0.22
0.15
1.61
3.86
i*.l*3
3.56
86.02
OIRFCT, PERCENT
ASH PYRITIC
SULFUR
2.80
<*.i*0
7.80
15.UO
25. 00
31.50
i*l. 00
99.65
2. 86
i*.61
9.12
16.01
26.31*
33.93
1*1*. <*7
99.16
2.86
-------
SPECIFIC GRAVITY ANALYSIS OF FLOHSTREAM NUMBER 25 (CONTINUED)
ORIGIN - UNIT NUMBER 15 I DESTINATION - UNIT NUMBER 2
USER HANDBOOK EXAMPLE PAGE 55
SIZE FRACTION AND HEIGHT
8M BY 28H
PERCENT OF FLOW
15.1*
28M BY 100M
PERCENT OF FLOW
7.7
O
CO
100M BY 325M
PERCENT OF FLOW
3. 7
COMPOSITE
FLOHRATE
2.2
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1. kO
1.1*0-1.50
1.50-1. 60
1 .60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
l.
-------
USER HANDBOOK EXAMPLE PACE !
SUMMARY OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 16
STREAM BLENDER
SIZE, INCHES OR MESH
1/2
BY
3M
SCREEN ANALYSIS-, PERCENT-
PRODUCT . i» 6. 18
FEED 1 51.31
FEED 2..... 0.00
ASH, PERCENT
PRODUCT.,,
FEED l...c
FEED 2....
, PVRITIC SULFUR, PERCENT
PROOUCT.
FEED 1.
FEED 2,
TOTAL SULFUR?
PROOUCT....
FEED 1.....
FEED 2.....
PERCENT
0. 00
0.42
0.42
0,00
0.98
0.98
0.00
BTU/LO, MOISTURE FREE
PRODUCT.... 14,535
FEED i............. . 14,535
FEED 2.. 0
8M
BY
28M
2<».63
27.37
0.00
6.97
6.97
0.00
0.86
0.86
0.00
1.39
1.39
0.00
28M
3Y
100M
15. 17
12. 7
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 26
ORIGIN - UNIT NUMBER 16 C DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAbE 57
SIZE FRACTION AND HEIGHT
1/2 BY 8M
PERCENT OF FLOW
1.6.2
8M BY 28M
PERCENT OF FLOW
24. 6
ro
M
o
28M BY 100M
PERCENT OF FLOW
15.2
100M BY 325M
PERCENT OF FLOW
14. 0
COMPOSITE
FLOWRATE
114.4
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-l.
-------
USER HANDBOOK EXAMPLE PAGE 58
SUMMER* OF THE PERFORMANCE CHARACTERISTICS OF UNIT NUMBER 17
STREAM BLENDER
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
PRODUCT 34.98
FEED 1 $9.06
FEED 2
ASH, PERCENT
PRODUCT
FEED 1........
FEED 2
PYRITIC SULFUR, PERCENT
PRODUCT ........
FEED 1
FEED 2 ,
TOTAL SULFUR, PERCENT
PRODUCT <
FEED 1.... .. ,
FEED 2
BTU/L8, MOISTURE FREE
PRODUCT Ik
FEED 1...
FEED 2
6
BY
2
4.98
9.06
3. CO
6.65
6.65
0.00
0.71
0.71
a. oo
1.34
1.34
0.00
>,522
0
2
BY
1/2
22.69
38.65
0.00
6.01
6.01
O.OQ
0.96
0.96
0.00
1.56
1.56
0.00
14,290
14.290
0
1/2
BY
8M
20.14
2.21
46.18
6.61
9.53
0.49
1.50
1.06
2.09
0.98
14,549
14,033
14,585
8M
BY
28H
10.07
24.63
6.97
9.35
6.97
0.87
2.05
0.86
1.39
2.60
1.39
14,420
14,004
14,421
28M
BY
100M
6.19
0.01
15.17
7.58
8.45
7.58
1.26
2.17
1.28
1.85
2.76
1.65
14,316
14,055
14,317
100M
BY
325M
5.72
0.01
14.02
7.63
7.49
7.63
1.88
2.23
1.83
2.47
2.82
2.47
13,970
13,883
13,971
COMP
100.00
100.00
100. GO
7.10
7.24
6.90
0.84
0.62
0.86
1.44
1.44
1.42
14,420
14,421
14,418
-------
USER HANDBOOK EXAMPLE PAGE 59
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 27
ORIGIN - UNIT NUMBER 17 C DESTINATION - UNIT NUMBER
18
SIZE FRACTION AND HEIGHT
6 9Y 2
PERCENT OF FLOW
35. 0
2 BY 1/2
PERCENT OF FLOW
22.9
1/2 BY 8N
PERCENT OF FLOW
20.1
8H BY 26M
PERCENT OF FLOW
10.1
28M BY 100M
PERCENT OF FLOW
6.2
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.1,0
1.1,0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.3 0-1. 35
1.35-1.1,0
1.1.0-1.50
1 .50-1 . 60
1.60-1. 70
1.70-1.80
1. BO-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
1.1*0-1. 50
1.50-1.60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1*0
l.
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 27 (CONTINUED)
ORIGIN - UNIT NUMBER 17 C DESTINATION - UNIT NUMBER 18
USER HANDBOOK EXAMPLE PAGE 60
SIZE FRACTION AND WEIGHT
100M BY 325M
PERCENT OF FLOW
COMPOSITE
FLOWRATE
280.7
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1. 40
1.40-1. 50
1 .50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1.35
1.35-1. 40
1.40-1. 50
1.50-1. 60
1.60-1.70
1.70-1. '80
1.80-SINK
DIRECT, PERCENT
WEIGHT
45. 11
24. 40
14. 56
6. 12
2. 78
1. 44
0.61
4.98
44.41
27. 77
8. 75
13. 75
3.36
0.91
0.24
0.80
ASH
l.i*3
3. 21
4.86
12.56
21.53
29.89
38.94
69.52
2.45
4.57
8.70
15.59
25.57
33.02
41.87
71.82
PYRITIC
SULFUR
0.12
0.33
0.49
1. 31
2. 34
3. 77
6. 25
28. 83
0.14
0.49
0 .88
1.54
2. 09
3.50
5.65
29.33
TOTAL
SULFUR
0 .66
0. 88
1. 07
1. 84
2.88
4.24
6.82
30.28
0. 74
1. 09
1.42
2.11
2.57
4.02
6.17
31.15
BTU/LB
1 5,355
14,907
13,909
12,682
11,077
9,723
8,269
2,145
15,355
14,907
13,909
12,682
1 1,077
9,723
8,269
2,360
WEIGHT
45.11
69.51
84.07
90. 19
92.97
94.41
95.02
100.00
44.41
72. 19
80.94
94.68
98.04
98.95
99.20
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL BTU/LB
SULFUR SULFUR
1.43
2.05
2.54
3.22
3. 77
4.17
4.39
7.63
2.45
3.26
3.85
5.5 e
6.24
6.49
6.58
7.10
0.12
0.19
0.24
0.32
0.38
0.43
0.47
1. 88
0. 14
0.28
0.34
0.52
0.57
0.60
0.61
0.84
0. 66
0. 74
0.80
0. 87
0.93
0. 98
1. 02
2.47
0. 74
0. 88
0.93
1.11
1. 16
1. 18
1.19
1.44
15,355
15,198
14,975
14,819
14,707
14,631
14,590
13.970
15,355
15,183
15,045
14,702
14,578
14,533
14,518
14,430
-------
USER HANDBOOK EXAMPLE PAGE ei
SUMMARY OF THE PRE-BREAKAGE PERFORMANCE OF UNIT NUMBER
CENTRIFUGE
18
SIZE, INCHES OR MESH
SCREEN ANALYSIS, PERCENT-
ASH, PERCENT
PYRITIC SULFUR, PERCENT
TOTAL SULFUR, PERCENT
aru/LB, MOISTURE FREE
6
9Y
2
2
BY
1/2
22.89
25.31
8.01
0.96
0.85
1.56
1 .46
lit, 290
I'M 392
1/2
BY
8H
20. 1<»
25. 03
6.61
7. 00
0. 65
1. 23
14»549
14,475
8M
3Y
28M
i n . n 7
lit, 1 1
6. 97
6 96
0.87
0. 76
1. 39
1.31
14,450
28M
BY
100M
61 Q
Q. n ^
7.58
7.35
1 . 28
1. 08
1. 85
14,367
100M
BY
325M
5.7?
7 35
7.53
7 52
1.88
1 ft ft
2. 2*t
1<».070
COMP
1 n n n n
inn n n
7. 1 n
7 . 1 n
0. fti*
Oai.
1. 44
1 .44
14. U7 n
-------
SUMMARY OF THE PERFORMANCE CHARftCTERISTICS OF UNIT NUMBER 18
CENTRIFUGE
UPPER FLOW STREAM = 99.0 PERCENT OF FEED
USER HANDBOOK EXAMPLE PAGE f>2
SIZE, INCHES OR MESH
6
BY
2
SCREEN ANALYSIS, PERCENT-
FEED...... 3I..98
PRODUCT 1 (UPPER STREAM) 19.16
PRODUCT 2 (LOWER STREAM) 19.16
ASM, PERCENT
FEED
PRODUCT 1 (UPPER STREAM),
PRODUCT 2 (LOWER STREAM),
PYRITIC SULFUR, PERCENT
FEED
PRODUCT 1 (UPPER STREAM)
PRODUCT Z (LOWER STREAM)
6.65
6.65
6.65
0.71
0.71
0.71
TOTAL SULFUR, PERCENT
FEED
PRODUCT 1 (UPPER STREAM),
PRODUCT 2 (LOWER STREAM)
6TU/LB, MOISTURE FREE
FEED 1<.,522
PRODUCT 1 (UPPER STREAM) 1<»,522
PRODUCT Z (LOWER STREAM) lt.,522
2
BY
1/2
22.89
25.31
25.31
8.01
7.t»l
0.96
0.85
0.85
1.56
1.1.6
1.1.6
11., 290
!<., 392
lt.,392
1/2
BY
8M
20.11.
25. 03
25. 03
6.61
7. 00'
7. 00
0.1*9
0.65
0.65
1.06
1.23
1.23
11., l. 75
!«.,<» 75
8M
BY
28M
10.07
!«,. 11
6.97
6.96
6.96
0.87
0.76
0.76
1.39
1.31
1.31
11., 1.50
28M
BY
10 OM
6. 19
9. 03
9. 03
7.58
7. 35
7.35
1.28
1. 08
1. 08
1. 85
1. 65
1. 65
1«M367
I'M 3 67
100M
9Y
325M
5.72
7.35
7.35
7.63
7.52
7.52
1.88
1.66
1.66
2.1.7
2.2«.
2.21.
13,970
11., 070
ll»,070
COMP
100.00
100. '00
100.00
7.10
7.10
7.10
0.81.
0.81.
1.1.1,
1.1.1.
11., 1.20
11., 1.20
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 38
ORIGIN - UNIT NUM3ER 18 U DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGC 6«
SIZE FRACTION ANO HEIGHT
6 BY 2
PERCENT OF FLOW
19.2
2 BY 1/2
PERCENT OF FLOW
25.3
1/2 BY 8M
PERCENT OF FLOW
25. 0
8H 8Y 28M
PERCENT OF FLOW
11.. 1
28H BY 100H
PERCENT OF FLOW
9.0
SPECIFIC
GRA VITY
WEIGHT
DIRECT, PERCENT
ASH PYRITIC
SULFUR
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1.0-1. 50
1.50-1. 60
1.60-1.70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.1.0
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1 .35-1.1.0
l.'.O-l. 50
1.50-1.60
1.60-1. 70
1 .70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. 1,0
l.'.O-l. 50
1.50-1.60
1.60-1. 70
1.70-1. 80
1. BO-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1. <*0
1.1*0-1.50
1 .50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
!»(..
27.
6.
18.
2,
0.
0.
0.
1.0.
29.
9.
16.
3.
0.
0.
0.
<»2.
30.
9.
13.
3.
0.
0.
0.
1.7.
26.
8.
10.
>t.
1.
0.
0.
51..
20.
8.
8.
3.
1.
0.
1.
0<*
ai*
97
75
21
17
03
00
69
30
56
35
60
87
20
-------
SPECIFIC GRAVITY ANALYSIS OF FLOHSTREAM NUMBER 28 (CONTINUED)
ORIGIN - UNIT NUMBER 18 U DESTINATION - UNIT NUMBER 0
USER HANDBOOK EXAMPLE PAGE 6<»
SIZE FRACTION AND HEIGHT
100M BY 325M
PERCENT OF FLOW
7.3
COMPOSITE
FLOWRATE
277.8
SPECIFIC
.•RAVITY
FLOAT-1. HQ
1.30-1. 35
1.35-1. M
1. «f 0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
WEIGHT
1*6. 25
2i*. i*2
13. 18
6,91
3. 06
1. 1*6
0.57
i». 11*
1*1*. 1*1
27. 77
8. 75
13.75
3.36
0.91
0.2<«
0.80
DIRECT, PERCENT
ASH PYRITIC
1.59
3.55
5.1*6
13.52
22.70
30.60
39. 1*1*
69.83
2.1*5
i*.57
8.70
15.59
25.57
33.02
1*1.87
71.82
SULFUR
0 .13
0.3<*
0.51*
1. 31*
2.28
3.72
6. 11*
28.78
0. 11*
0.1.9
0.88
1.5i*
2.09
3.50
5.65
29.33
TOTAL
SULFUR
0.67
0.90
1. 11
1.88
2. 80
i*.20
6.71
30.21*
0. 71*
1.09
1.1*2
2.11
2.57
<*.02
6.17
31.15
BTU/L8
15,355
1<*,907
13,909
12,682
11,077
9,723
8,269
2,155
15,355
11., 907
13,909
12,682
11,077
9,723
8,269
2,360
CUMULATIVE, PERCENT
HEIGHT ASH PYRITIC TOTAL
SULFUR SULFUR
BTU/LB
1*6.25
70.67
83.85
90. 77
93.83
95.29
95.86
100.00
1*1*. 1*1
72.19
80.91*
91*. 68
98. 04
98.95
99.20
100.00
1.59
2.2 7
2.7 7
3.5S
i*. 2 1
i*.62
i*.8 2
7.52
2.45
3.2 6
3.85
5.56
6.2*1
6.1*9
6.56
7.10
0.13
0.20
0.26
0.31*
0.1*0
0.1*5
0.1*9
1.66
0.14
0.23
0.34
0.52
0.57
0.60
0.61
0.81,
0.67
0.75
0.81
0.89
0.95
1. 00
1.03
2.21*
0.74
0.89
0.93
1.11
1.16
1.18
1.19
1.1*1*
15,355
15,200
11,, 997
li», 821
li»,699
li*, 623
li., 585
li»,070
15,355
15,183
15,0i»5
14,702
14,578
14,533
14,518
14,420
-------
SPECIFIC GRAVITY ANALYSIS OF FLOHSTREAM NUMBER 29
ORIGIN - UNIT NUMBER 18 I DESTINATION - UNIT NUMBER
USER HANDBOOK EXAMPLE PAGE 65
SIZE FRACTION AND HEIGHT
6 BY 2
PERCENT OF FLOW
19.2
2 8Y 1/2
PERCENT OF FLOW
25. 3
t-o
I—'
oo
1/2 EY 8M
PERCENT OF FLOW
25. 0
8M BY 28M
PERCENT OF FLOW
II,.1
28M BY 100M
PERCENT OF FLOW
9.0
SPECIFIC
GRAVITY
FLOAT-l. 30
1.30-1. 35
1.35-1. 1*0
1.1.0-1.50
1.50-1. 60
1.60-1.70
1.70-1.60
1.80-SINK
FLOAT-l. 30
1.30-1. 35
1.35-1.1,0
1 .1*0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 60
1.80-SINK
FLOAT-l. 30
1.30-1. 35
1.35-1. *»0
1.<*0-1. 50
1.50-1.60
1.60-1. 70
1.70-1.80
1.80-SINK
FLOAT-l. 30
1.30-1.35
1.35-1. 1*0
1.1.0-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1. BO-SINK
FLOAT-l. 30
1.30-1. 35
1.35-1.1*0
1.1,0-1. 50
1.50-1.60
1.60-1.70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
WEIGHT
kit. 0<»
27. 6i»
6. 97
18.75
2.21
0. 17
0. 03
0. 00
1*0.69
29. 30
8.56
16. 35
3.60
0.87
0. 20
0.1,3
1*2.1*1
30,33
9.i»i»
13. 00
3.<«1
0.77
0.18
0. 1,6
1*7. 1.9
26. 88
8. 2<*
10.80
9
5.35
5.88
6.11
7.35
0.15
0.31.
0.1.1
0.66
0.70
0.71
0.71
0.71
0.15
0.33
0.1*1
0.62
0.68
0.70
0.71
0.85
0.12
0.22
0.29
0.1*3
0.1*8
0.50
0.51
0.65
0.15
0.21*
0.29
0.1*2
O.i*9
0.53
0.5i*
0.76
0.16
0.21*
0.31
0.1*2
0.1.9
0.55
0.59
1.00
0.80
1.00
1.06
1.30
1.3i»
1.31.
1.3k
1.31*
0.79
0.96
1. 03
1.23
1.28
1.31
1.32
1.1.6
0.72
0.82
0.87
1. 01
1.06
1. 08
1.09
1.23
0.69
0.78
0. 83
0.96
1. 03
1. 07
1.08
1.31
0.71
0.80
0.85
0.96
l.Oi*
1.10
1.13
1.65
15,355
15,181
15,069
11., 610
li*, 532
li«, 521,
li»»522
1<»»522
15,355
15,167
15,030
1U, 626
li*, 1*96
li., 1. 1.2
li*, 392
15,355
15,168
15,021.
11., 701*
lit, 578
11*, 51,1
li*, 530
1 1. , 1, 75
15,355
15,193
15,065
1<*,789
li*, 630
li»,565
Ii*,5it6
15,355
15,23«*
15,101
11,, 889
li»,732
H», 635
11*, 593
li,, 367
-------
SPECIFIC GRAVITY ANALYSIS OF FLOWSTREAM NUMBER 29 (CONTINUED!
ORIGIN - UNIT NUMBER 18 L DESTINATION - UNIT NUMBER 2
USER HANDBOOK EXAMPLE PAGE 66
SIZE FRACTION AND HEIGHT
100M BY 325M
PERCENT OF FLOW
7.3
COMPOSITE
FLOMRATE
2.8
SPECIFIC
GRAVITY
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1. 80
1.80-SINK
FLOAT-1. 30
1.30-1. 35
1.35-1.40
1.40-1. 50
1.50-1. 60
1.60-1. 70
1.70-1.80
1.80-SINK
DIRECT, PERCENT
WEIGHT
46. 25
24.42
13.18
6.91
3. 06
1.46
0.57
4.14
44.41
27. 77
6.75
13.75
3.36
0.91
0.24
0. 8U
ASH
1.59
3.55
5.46
13.52
22.70
30.60
39.44
69.83
2.45
4.57
8.70
15.59
25.57
33.02
41.87
71.82
PYRITIC
SULFUR
0. 13
0.34
0.54
1.34
2. 28
3.72
6. 14
28.78
0.14
0.49
0 .88
1.54
2.09
3.50
5.65
29.33
TOTAL
SULFUR
0.67
0.90
1. 11
1.88
2.80
4.20
6.71
30.24
0.74
1. 09
1.42
2.11
2.57
4.02
6.17
31.15
BTU/LB
15,355
14,907
13,909
12,682
1 1,077
9,723
8,269
2,155
1 5,355
14,907
13,909
12,682
11,077
9,723
8,269
2,360
WEIGHT
46.25
70.67
33. 85
90.77
93.83
95.29
95. 86
100.00
44.41
72.19
80.94
94.68
98.04
98.95
99.20
100.00
CUMULATIVE, PERCENT
ASH PYRITIC TOTAL BTU/LB
SULFUR SULFUR
1.59
2.27
2.77
3.59
4.21
4.62
4.82
7.52
2.1*5
3.26
3.85
5.56
6.24
6.49
6.5 f
7.10
0.13
0.20
0.26
0.34
0.1*0
0.45
0.49
1.66
0.14
0.28
0.34
0.52
0.57
0.60
0.61
0.6i»
0.67
0. 75
0.81
0.89
0.95
1. 00
1.03
2.24
0.74
0.88
0.93
1.11
1.16
1.18
1.19
1.44
15,355
15,200
14,997
14,821
14,699
14,623
14,585
14,070
15,355
15,183
15,045
14,702
14,576
14,533
14,518
14,430
-------
SUMMARY DATA FOR UNITS
UNIT NUMBER UNIT TYPE
1 11 (ROTARY BREAKER)
2 1.1 (BLENDER (ADDS WATER))
3 23 (WET UPPER SCREEN)
i» 2i» (WET LOWER SCREEN)
5 1*1 (STREAM BLENOFR)
6 6 (TWO-STAGE 6AUM JIG)
7 i*l (STREAM BLENDER)
8 16 (SECONDARY MULTIPLE ROLL CRUSHERJ
9 i*l (STREAM BLENDER)
10 23 (WET SINGLE DECK SCREEN)
11 1 (CONCENTRATING TABLE)
12 1.1 (STREAM BLENDER)
13 7 (FROTH FLOTATION CELL)
H. <»1 (STREAM BLENDER)
15 52 (CENTRIFUGE)
16 t»l (STREAM BLENDER)
17 1.1 (STREAM BLENDER)
18 52 (CENTRIFUGE)
DECISION VARIABLES
20.000
67.500
1.500
0.500
1.620
0.275
0.023
1.580
20.000
99.000
12.000
15.000
15.000
15.000
(>.000
YIELD
(PERCENT)
USER HANDBOOK EXAMPLE PAGE 67
BTU RECOVERY HATER ADDED
(PERCENT) GPM
6.000
71. «•
56.1
8<».7
60.7
65.7
85.7
86.6
99.000 3.000
-------
SUMMARY DATA FOR FLOWSTRFAMS
USEP HANDBOOK EXAMPLE PAGE 68
FLOWSTREAM
NUMBER
1
2
3
-------
SUMMARY DATA FOR FLOWSTREAMS
USER HANDBOOK EXAMPLE PAGE 69
ASH
BTU/LB
FLOWSTREAM ORIGIN DESTINATION
NUMBER UNIT NO. UNIT NO.
ho
bo
M
24
25
26
27
28
29
15
15
16
17
18
18
U
I
C
C
U
L
0
2
17
18
0
2
FLOWRATE
TPH (PERCENT)
222.
2.
280.
277.
2.
2
2
7
8
8
77.55
77.55
6.90
7.10
7.10
7.10
SULFUR
(PERCENT)
17.09
17.09
0.86
0.81.
0.84
0.8t»
SULFUR L8S S02/
(PERCENT) MILLION 8TU
18. Id 2.547 142.41
18.14 2i5<»7 142.41
1.42 14,418 1.97
1.44 14,1.20 1.99
1.44 14, 420 1.99
1.44 14,420 1.99
MOISTURE HATER
(PERCENT) GPM
4.00
99.74
15.53
3.00
93.70
37.0
3,405.0
84.1
201.5
34. k
167.1
THIS SIMULATION REQUIRED 6,271 CELLS OF WORKING STORAGE
-------
APPENDIX B
USER HANDBOOK COST EXAMPLE
223
-------
M
ro
UNIT NUMBER
1
2
3
k
5
6
7
8
9
10
11
12
13
i
-------
USER HANDBOOK COST EXAMPLE PAGE 2
Ln
FLOWSTREAM NUMBER
1 (FEED)
2
3
it
5
6
7
3
9
10
11
12
13
1<«
15
16
17
18
19
20
21
22
23
24
25
ORIGIN - UNIT NUMBER
0
DESTINATION - UNIT NUMBER
1
26 (CLEAN GOul PRODUCT)
1
1
2
3
3
t*
tt
5
6
6
7
8
S
9
9
10
11
12
13
14
11*
15
15
Ib
17
U
L
R
C
U
L
U
L
R
C
L
U
R
C
L
U
C
0
2
3
20
4
5
6
11
11
7
8
12
9
12
1C
11
17
13
14
18
15
12
16
17
0
-------
USER HANDBOOK COST EXAMPLE PAGE 3
FLOWST.^EAM NUMBER
27
26
29
30
31
ORIGIN - UNIT NUMBER
18 L
18 U
19
20 U
2J L
DESTINATION - UNIT NJMBE3
0
19
2
0
a
-------
FEED TO UNIT NUMBER 1
SPECIFIC GRAVITY ANALYSIS OF FLOrfSTREAM NUMBER 1
USER HMDBOOK COST EXAMPLE PAGE 4
SIZE FRACTION AND HEIGHT
6 BY 3/4
PERCENT OF FLOH 39.7
3/4 BY 0
PERCENT OF FLOH 70.2
COMPOSITE
FLOHRATE
£.00.0
SPECIFIC
GRAVITY
FLOAT-1.40
1.40-1.45
1.45-1.50
1.50-1. 55
1.55-1.60
1.60-SINK
FLOAV-1.40
1.40-1.45
1.45-1. 50
1.50-1. 55
1.55-1. 60
1.60-SINK
FLOAT-1.<»0
l.i»0-l. 45
1.45-1. 50
1.5G-1.55
1.55-1. 60
1.60-SINK
HEIGHT
46.42
2.67
1.22
1. 06
1.55
<»7.08
47.23
4.49
3. 00
2. Ok
1.99
41.25
i»6.99
3.95
2.47
1.75
1.86
42.98
DIRECT,
ASH
i*. 75
13.33
23.63
29.53
55.96
76.89
4.03
14.67
16.61
21.69
35.99
7i». 68
4.71
l^.ifD
17.6V
23.10
kO.lk
76.05
PERCENT
TOTAL
SULFUS
0. 78
0. 76
0.93
0 .51
0.<»2
0.41
0. 78
0.80
0.94
0.67
0. 76
0 .47
0.78
0.79
0.94
0.61
0.68
0*45
6TU/LB
1<«,003
12,352
10,990
9,380
5,263
2,060
13,810
11,737
10,219
9,712
7,707
2,388
13,867
11,861
10,332
9,742
7,101
2,281
HEIGHT
46.42
49.09
50.31
51.37
52.92
100.00
47.23
51.72
54.72
56.76
58.75
100.30
46.99
50.94
53.41
55.16
57.J2
100.00
ASH
4.75
5.22
5.66
6.16
7.61
41.17
4.69
5.56
6.16
6.72
7.71
35.34
4.71
5.46
6.02
6.56
7.66
37.07
CUMU.ATIVE, PERCENT
TOTAL BTU/L3
SULFU?
0. 79
0.73
0.73
0.78
0.77
0.69
0.79
0.79
0.79
0.79
0.79
0.63
0.73
0.79
0.79
0.7)
0.73
0.61.
14,003
13,913
13,842
13,761
13,512
8,120
13,810
13,630
13,443
13,309
13,119
8,693
13,867
13,711
13,555
13,434
13,228
6, 522
-------
USER HANDBOOK OOST EXAMPLE PAGE 5
ro
t-o
(X
UNIT NUMBER
b
7
a
3
10
11
12
13
I1*
15
1&
17
IS
19
20
UNIT TYPE
21 (SCALPING SCREEN)
1*1 (BLFNJER)
5(8 ;ELL BAUM JIG)
23 (SCREEN)
li* (C.RUSHE*)
Zk (SCREEN)
i*l (SUMP (BLENDER))
3 (CLASSIFYING CYCLONE)
23 (SCREES)
i*l (CENTRIFUGE <6LENOER>>
1,1 (SU1P (bLENOER))
23 (SCREEN)
-------
SUMMARY DATA FO* FLOHSTREftMS
USER HANDBOOK COST EXAMPLE PAGE 6
flSH
TOTAL
BTU/LB
FLOWSTREAI
NUMBER
i
2
3
"
5
6
7
6
9
10
11
12
13
14
15
16
17
18
19
2Q
21
22
23
ORIGIN DESTINATION
UNIT NO. UNIT NO.
a
1 U
1 L
2
3 R
3 G
4 U
4 L
5
6 U
6 L
7
8 R
3 C
9 L
9 U
10
11
12
13
14 R
14 C
15 L
1
0
2
3
20
*
5
6
11
11
7
8
12
9
12
10
11
17
13
14
13
15
12
FLOWRATE SJLFJR
TPH (PERCENT) (PERCENT)
600.
0.
600.
606.
223.
383.
95.
287.
95.
201.
85.
85.
20.
65.
0.
65.
65.
353.
20.
20.
19.
0.
0.
0
0
0
4
3
0
4
6
4
9
6
8
0
8
C
7
7
C
0
0
2
9
0
37. 07
41. 17
37.07
37.35
73. 03
16.56
7.83
19.45
7.83
19.45
19.45
19. 45
63.28
6. 12
6.12
6. 12
6. 12
13. 98
63.22
63.22
63. 89
48.24
48.24
0.6^
0.60
0 .64
O.b4
0.47
0.71,
0.77
0.73
0.77
0. 73
0. 73
0.73
0.56
0.79
0.73
0. 79
0. 73
0.75
0.56
0.56
0. 55
0.66
0.66
3,522
3,120
S,522
3,473
2,754
11 , (308
13,476
11,254
13,476
11,254
11,254
11,254
3,969
13,470
13,470
13,470
13,470
12,240
3,^79
3,979
3,383
6,114
b,114
LBS SQZS
MILLION 3TU
1.
1.
1.
1.
3.
1.
1.
1.
1.
1.
1.
1.
2.
1.
1.
1.
1.
1.
2.
2.
2.
2.
2.
50
47
50
51
38
26
14
30
14
30
30
30
80
17
17
17
17
23
79
79
84
16
16
MOISTURE
CERCENT)
0. 00
0. 00
0.00
0. 00
0.00
0.00
0. 00
0.00
0.00
0. 00
0. 00
0.00
0. 00
0. 00
0.00
0.00
0. 00
0. 00
0. 00
0.00
O.JO
0.00
0. 00
HATER
GPM
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
-------
SUMMARY OATH FCR FLOHSTREAMS
USER HANDBOOK 30ST EXAMPLE PA&E 7
ASH
TOTAL
BTU^LB
FLO KSTREAH ORIGIN DESTINATION
NUMBER UNIT NO. UNIT NO.
2.
25
W 26
o
27
2B
29
30
31
13 U
16
17 C
18 L
18 U
19
20 U
20 L
16
17
0
0
19
2
C
a
FLCWRATE SJLFJR
TPH (PERCENT) (PERSEMT)
0.9
0.9
363.9
12. 6
6. if
6. if
222.2
1. 1
.38
.30
MOISTURE
PERCENT)
0.
0.
0.
0.
0.
0.
0.
0.
00
00
00
00
DC
00
00
00
HATER
GPM
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
THIS SIMULATION RE3UIREO 1,796 CELLS OF WORKING STORAGE
-------
USER HANDBOOK SOST EXAMPLE PAGE 8
LISTING OF COST ELEMENT VALUES FOR USER HANDBOOK COST EXAMPLE
TOTAL PREPARATION PLANT EQUIPMENT COST 512,895.75
6*16 FT SINGLE DECK SCALPING S3REEN 17,500.01]
EIGHT CELL BAUM TYPE JIG 175,987.99
6*16 FT DOUBLE DECK OEWATE.RIN3 SCREENS k , 0 0 0 . 0 0
CLEAN COAL BELT....36 INCH dIDE l
-------
USE* HANDBOOK COST EXAMPLE PAGE 9
LISTING OF COST ELEMENT VALUES FOR USE? HANDBOOK COST EXAMPLE
RAW COAL AND REFUSE HANDLING EQUIPMENT 300.000.00
US'IT-TRAIN LOADING FACILITY 500,000.00
CONTINGENCY 511*,003.09
PREPARATION PLANT CONTINGENT 230,803.09
RAW COAL STORAGE CONTINGENCY 63,600.00
OTHER FACiLiTIES CONTINGENCY 219,600.00
OPERATING AND MAINTENANCE C3ST 2 ,<»79, 822 . 80
LABOR- SUPERVISORY (NON-UNION) 68,6<»a.OG
LAi3CR - OPERATING * MAINTENANCE (UNION!. i»72,6BG.Oi)
Fi\lNG£ BES-EFIT3 - NON-UNION 17,160.00
FRINGE BENEFITS - UNION y9.362.3C
OTHER OVERHEAD 92,0^0.00
OPERATING SUPPLIES Z<»1,830.00
OPERATING MAINTENANCE Z30,890.00
MAJOR. MAINTENANCE ' 209,0^*0.00
ELECTRICITY 113,880.00
SUBCONTRACT SERVICES 93<», <»!»0 . 00
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USER HANDBOOK COST EXAMPLE PAGE 10
PROJECT CASH FLOW DESCRIPTION FOR USER HANDBOOK COST EXAMPLE
DEPRECIABLE
ANNUAL CAPITAL
YEAR PRODUCTION INVESTMENT
0 0.00 39
-------
USER HANDBOOK COST EXAMPLE PAGE 11
DISCOUNTED CASH FLOH ANALrSIS FOR USE? HANDBOOK COST EXAMPLE
YEAR
0
1
2
t-o 3
•e-
4
5
6
7
s
9
10
TAXABLE
INCOME
0.00
439939.36
439939.36
439939.38
439939.38
439939.38
439939.36
439939.36
439939.36
439939.38
433939.38
TAXES
PAID
0.00
219969.69
219969.69
219969.69
219969.69
219569.69
219969.69
219969.69
219969.69
215969.69
219569.69
CASH FLOH
AFTER
TAXES
Q. 00
614038.72
614038.72
614038.72
614038.72
614036.72
614038.72
614038.72
614038.72
614038.72
614036.72
NET
CASH FLOW
-3940690.34
614038.72
614038.72
614038.72
614038.72
614038.72
614038.72
614036.72
614038.72
614038.72
614038.72
DISCOUNT
FACTOR
1. 090000
1. 000000
.917431
. 841680
.772183
.708425
.649931
.596267
.547034
.501866
.460428
DISCOUNTED
CASH FLOH
-4295352.4657
614038.7224
563338.2774
516824.1077
474150.5575
435000.5115
399083.0381
366131.2276
335900.2088
308165.3292
282720.4855
UNIT SELLING PRICE
3.5026 RATE OF RETURNS .Q9QO INCOME TAX RATEs .5000
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TECHNICAL REPORT DATA
(Please read fnuructions on the reverse before completing}
1. REPORT NO.
EPA-600/7-80-010a
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Coal Preparation Plant Computer Model:
Volume I. User Documentation
5. REPORT DATE
January 1980
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Frederick K. Goodman and Jane H. McCreery
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Battelle Memorial Institute
Columbus Laboratories
505 King Avenue
Columbus, Ohio 43201
10. PROGRAM ELEMENT NO.
EHE623A
11. CONTRACT/GRANT NO.
68-02-2163, Task 814
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final: 7/76 - 7/79
14. SPONSORING AGENCY CODE
EPA/600/13
15. SUPPLEMENTARY NOTES IERL_RTp pro;ject officer is James D. Kilgroe, Mail Drop 61,
919/541-2851.
s. ABSTRACT
two-volume report describes a steady state modeling system that
simulates the performance of coal preparation plants. The system was developed
originally under the technical leadership of the U.S. Bureau of Mines and the spon-
sorship of the EPA. The modified form described in this report, written in FOR-
TRAN, was developed by Battelle for the EPA. The original modifications made the
program usable in evaluating an advanced coal cleaning facility being constructed at
Homer City, PA. Subsequent changes allowed the model to be used for a wider
range of performance and cost evaluations. Initial changes to the original program
increased the number of process operations which could be simulated, and simpli-
fied program operation. Later modifications permitted the calculation of plant water
flows and the estimation of plant costs. Volume I contains user documentation, and
Volume n provides process documentation. Volume I describes: the manner in
which coal flows are represented, the mathematical approach of the various unit
operations, the cost evaluation approach, preparation of the input, and interpreta-
tion of the output (the last two in terms of an example). Program documentation
begins in Volume II with a discussion of basic documentation principles , followed by
presentation of each routine and common block in terms of these principles.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDEDTERMS
c. COSATI Field/Group
Pollution
Coal
Coal Preparation
Mathematical Models
FORTRAN
Performance Evaluation
Cost Estimates
Pollution Control
Stationary Sources
Coal Cleaning
13B
08G
081
12A
09A
05A
14A
13. DISTRIBUTION STATEMEN1
Release to Public
19. SECURITY CLASS (This Report/
Unclassified
21. NO. OF PAGES
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
235
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