COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

A BRIEF OVERVIEW OF THE PROCESS MODELING/SIMULATION

AND DESIGN CAPABILITIES OF METSIM

John Bartlett1, Alex Holtzapple2 and *Curtis Rempel3

1
PROWARE
Tucson, Arizona, USA
2
PROWARE
Belo Horizonte, MG, Brazil
3
PROWARE
Quesnel, BC, Canada
(*Corresponding Author: Curtis.Rempel@usask.ca)

ABSTRACT

METSIM is a powerful program capable of modelling and simulating every known metallurgical
and inorganic chemical process. METSIM is used by companies throughout the world to design, simulate
and control operations from mine to tailings and everything in between. At its absolute simplest, METSIM
can be used to create a process flowsheet. METSIM modules and built-in unit operations cover mass and
energy balances for either steady-state or dynamic simulations of mine, stockpile, heap leach, material
handling, comminution, beneficiation, hydrometallurgy, pyrometallurgy, gas and steam handling, and
tailings management processes. Data for the material being processed can include mineralogy, particle size
analysis, grade by size or multicomponent size analysis, washability data, mechanical, physical and
thermodynamic properties. METSIM is written in APL (A Programming Language). Unlike C++, APL is
simple and easy to learn, allowing the user to program whatever they can imagine, without first obtaining a
degree in computer science. METSIM can also interface with EXCEL and other software through dynamic
data exchange (DDE), allowing data to be imported and exported for viewing, analyzing and controlling.
METSIM can answer simple or complex metallurgical and process questions allowing the user to predict
and engineer without the issues of clumsy and tortuous spreadsheets.

KEYWORDS

METSIM, Process design, simulation, control.

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

INTRODUCTION

METSIM is a powerful program capable of modelling and simulating every known metallurgical
and inorganic chemical process. For more than 30 years, its developers have focused their efforts towards
maintaining a program capable of modeling well-defined processes as well as theoretical developments.
Given the flexible nature of the program’s platform, users may select from over 200 pre-programmed unit
operations or create APL subroutines to design their own. Currently, METSIM is used in over 50 countries
for mass and energy balances for either steady-state or dynamic simulations of mine, stockpile, heap leach,
material handling, comminution, beneficiation, hydrometallurgy, pyrometallurgy, gas and steam handling,
and tailings management processes. New unit operations and processes are endlessly developed in industry
and therefore will continue to drive METSIM to expand its capabilities.

THE BASICS

At its simplest METSIM can be used to produce flowsheets. Figure 1 below shows a simple
crushing circuit flowsheet created in METSIM. The flowsheet contains typical unit operation symbols
which are easily identified as screen, jaw crusher, conveyors and a stockpile. The unit operations included
in METSIM cover the full range of common processes as well as several proprietary unit operations.
Streams join the unit operations to indicate the direction of material flow. From here the level of detail is
strictly under the control of the user.

Figure 1 - METSIM Flowsheet

Components of the process, along with their physical and chemical properties, can be added to the
model from a large database included in METSIM. Physical and chemical processes can be calculated
within the unit operations. All unit operations have algorithms based on commonly accepted textbook
calculations with which the output streams are calculated. Many unit operations contain proprietary

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

algorithms for calculating complex units such as hydrocyclones. In the hydrocyclone unit operation the
user can choose between the KREBS (gMax), Lynch, Plitt or Modified Plitt algorithms. If the user does not
like the algorithm present in the unit operation, they can create their own using the APL programming
language, or simply override the unit operation output and write directly to the stream. Although only one
section of a larger model is shown in Figure 1, multiple sections can be added to encompass an entire
operation from mine to tailings inclusive. METSIM can generate basic mass and energy balances for a
single unit operation or model complex multi-unit, multi-component processes using algorithms involving
multidimensional inputs. The level of complexity is in the hands of the user.

MODULES AND APPLICATIONS

METSIM is offered as a modular program, meaning that companies and individuals may purchase
a simple mass balancing program for beneficiation and hydrometallurgical processes or may include
modules for material handling, comminution, pyrometallurgy, gas and steam handling, and dynamic
simulation for mines, stockpiles, heap leaching, and tailings management processes. Modules offered are
shown in table 1.

Table 1 - METSIM Modules And Applications In Industry

MODULE DESCRIPTION
BASE/MASS BALANCE This module performs mass balance calculations around each unit operation
MODULE and includes Chemical, Mineral Beneficiation and Hydrometallurgical
models.
COMMINUTION & This module includes Crushing, Grinding, Classification, Plant Material
GRAVITY Balances, Gravity Separation, Dense Media, Coal Preparation, Washability
SEPARATION MODULE and Liberation Models.
HEAT BALANCE This module performs heat balance calculations around each unit operation
MODULE and reports temperatures and the heat content for each stream. Heat losses
and heats of reaction are also calculated and reported. It includes an extensive
Thermodynamics Database and several Pyrometallurgical models.
DYNAMIC Dynamic simulation capability is being added to each unit operation as there
SIMULATION & HEAP is a demand for it; all operations concerned in heap leaching have already
LEACHING MODULE been provided with dynamic simulation. The heap leach module performs
mass balances around the heap leach process including chemical reactions,
precipitation and evaporation, solids and water inventories, and process
controls. The model is non-steady state and generates time dependent plots of
all critical variables in the operation. It includes DDE and PID Controllers,
Heap Leaching, Solar Energy/Weather Module w/Solar Pond. Used to model
processes that are time dependent.
MINE MODULE The Mine Module allows import of drill-hole data, the mine block model and
the mining sequence. The feed to the waste dumps, heaps, stockpiles and
plant can then be taken directly from the mine. This allows dynamic
simulation over the life of the mine.
CONTOURING Used for building complex mine, stockpile, heap leach, and tailings models
MODULE from DXF contour files and for displaying detailed data graphically.
METCOST, OPERATING The Operating Cost Module is designed to enable the user to use the data
COST MODULE generated by the flowsheet model to generate tables of operating costs. Costs
are output in spreadsheet format and can be itemized by flowsheet section,
unit operation, and cost types. A series of routines are provided in a menu
structure for input, calculation, editing and output. Operating costs can be
determined, at any time following the calculation of a model. This module
includes OPCOST, an advanced program for calculating mine capital and
operating costs.

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ENGINEERING The Engineering Module sizes equipment, generates equipment lists, adds
MODULE instrumentation, generates instrumentation lists, and simulates process
control systems.

Combining all modules into a single model allows for simulation of nearly any process from
beginning to end, and given the importance of recycle flow convergence, a single model to accomplish this
feat is invaluable. METSIM has been, and is currently, used for the following applications, though it is not
limited to this list.

ƒ Copper, nickel, uranium, gold, and silver heap leaches

ƒ Incinerators for military wastes at a superfund site
ƒ Electric furnace for EAF dust
ƒ Selenium decontamination process
ƒ Chloride process for titanium dioxide
ƒ HCl process for high purity alumina
ƒ Rare earth solvent extraction processes
ƒ Large-scale potash solar ponds
ƒ 100,000 ton per day grinding circuit
ƒ Potash, soda ash and phosphate plants
ƒ Dynamic model of lead refining
ƒ Sulfuric acid plants
ƒ Aggregate and gravel plants
ƒ Copper, moly, lead, zinc concentrators
ƒ HCl leach and magnesium electrolysis
ƒ Zinc and gold pressure leach plants
ƒ FeCl3 leach plants for molybdenum
ƒ NH3 leach process for brass scrap
ƒ Placer and CIP gold cyanidation plants
ƒ Uranium acid/carbonate leach plants
ƒ Outokumpu and INCO flash smelters
ƒ Copper, lead, zinc, nickel smelters
ƒ Precious metal and copper refineries
ƒ Dense media coal preparation plants
ƒ Nickel hydromet and smelting processes
ƒ Magnesium and aluminum processes
ƒ Direct iron ore reduction processes
ƒ Beryllium and indium processes

FEATURES

Although the focus of METSIM is accurate calculations and algorithms, a simple-to-use interface
offers users of all abilities a platform for model creation. Features, such as those outlined below, are
included with all modules. In conjunction with the modules listed above the features of METSIM make it
an invaluable tool for de-bottlenecking and optimization tasks.

Mass balancing based on design criteria:

- Detailed equipment sizing and equipment lists;
- Steady-state simulation: mass and energy balancing;
- Parameterization to simulate existing/operating plants;
- Dynamic simulation for time-varying parameters.
Flowsheeting:
- Easy to add new unit operations;
- Unlimited number of unit operations and flow streams;
- Flowsheet and dynamic graphics;

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

- Capable of calculating single, multiple or all unit operations;

- Robust proprietary flowsheet convergence algorithm;
- Full graphical interface.
Chemistry:
- Extensive thermodynamic database;
- Chemical kinetics and phase equilibria;
- Eight solid, liquid, molten, and gas phases.
Process controls:
- Feedback, feed forward, pH and PID controllers;
- Logic/expert systems;
- User-defined equations and algorithms.
Compatibility:
- Spreadsheet interface to Excel via dynamic data exchange;
- DXF interface with AutoCAD.

MATERIAL AND PROCESS DESIGN DATA

Detailed data for the material being processed, including mineralogy, particle size analysis, grade
by size or multicomponent size analysis, washability data, mechanical, physical and thermodynamic
properties may be included for all flow streams. Process data may include equipment sizing, control
strategies, equipment availabilities, chemical reaction efficiencies, heat losses/gains, reagent and material
costs, meteorological data, and any other item that impacts the process. An example of mineralogical data
within a flow stream is shown in figure 2.

Figure 2 - METSIM Stream Properties Window Showing Mineralogical Data in the Solids Fraction

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

Inclusion of
o particle sizee distributions (PSDs) by miineral is possibble using the multicomponen
m nt
particlle size (also kn
nown as gradee by size) featuure. In the graaph shown in figure
f 3, multiicomponent sizze
distribbutions are sho
own by individdual PSDs plottted for NaCl, KCl,
K CaSO4, and a insolubles for a plant feeed
stream
m. Changes to thet multicompoonent size anallysis due to unit operations suuch as flotationn, screening annd
crushiing are calculatted and trackedd throughout thhe model.

Figure
F 3 - MET
TSIM Multicom
mponent Size Analysis
A (Gradde by Size)

Meteorolog gical data mayy greatly affecct any processs that is expossed to nature which includees
nearlyy all processes. Figure 4 summ marizes the typpe of meteorological data thaat METSIM is able to manage.
Meteoorological dataa is crucial in the
t correct modelling of heapp leach, tailinggs pond and evvaporation ponnd
processses for obviouus reasons.

Figure
F 4 - Annuual Meteorologgical Data Chaart for A METS
SIM Model

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

Using minimum, average and maximum conditions METSIM can create scenarios to represent the full
range of weather related effects on a given operation. If desired this can be programmed for extreme
weather events to determine if overflow ponds and catchments are sufficiently sized.

Interfacing with AutoCAD DXF files allows for detailed dynamic simulation of mine, stockpile,
heap leach and tailings management facilities along with the use of the METSIM Contouring module. An
example of contours for a heap leach simulated in METSIM is shown in Figure 5. The ability to read DXF
files into METSIM removes any restriction on design dimensions or shape as the actual shape and
dimensions of the heap, stockpile, or tailings pond can be used directly. Detail is not lost due to gross
approximations of non-linear objects.

Figure 5 - Resulting Import of AutoCAD DXF file Into A METSIM Heap Leach Model

A PROGRAMMING LANGUAGE (APL)

The APL programming language, that METSIM is based on, was first developed by the Canadian Kenneth
E. Iverson in the late 1950’s and the early 1960’s. APL was derived from the Iverson mathematical
notation developed by Iverson for teaching mathematics. APL’s utility for processing data in the form of
scalars, vectors and matrices, very quickly and with a minimal number of coding lines make it the optimal
choice for METSIM. Some of the fundamental characters and their use is shown in table 2. Within
METSIM, the APL language can be used to build or modify simple calculations using the built in value
functions or math functions already in METSIM, or to create user stand-alone functions which can be
called in unit operations and many other locations in METSIM. If the user desires, the unit operation
algorithm can be replaced entirely by a user algorithm programmed in APL and called as a function. APL
is a simple language and it is well known that the code line ratio is typically 1 line of APL code to 20 lines
of C++ code. This compactness provides a lot of power in a small space.

METSIM has over 600 pre-built Value Functions and Mathematical Functions already
programmed and ready for use. These pre-built functions cross the full range of information users may
want to see in their models or mathematical manipulations that may be required. METSIM Value
Functions can provide outputs such as density and specific gravity, pressure, temperature, specific volume,

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

mass, molar and volumetric flowrates, particle size distribution, steam, air, heat content and numerous
others. The mathematical functions available for the user cover date and time, matrix manipulation and
interpolation, including two-way interpolation, vector manipulation, temperature, text, trigonometry and
many other more complex mathematics based manipulations of data.

Table 2 - APL Characters and Use in METSIM.

Symbol Function Name Keystroke Use(s)

⏐ rho or reshape Alt-r create or determine the size of an array
… iota or index Alt-i return consecutive integers from 1 to x
left arrow or assignment Alt-[ assign a value to a variable
/ slash or reduction / repeat an operation in a series of values
determine if values are present in an
≠ member of Alt-e
array
? random ? generate random values
⋅ times Alt-- multiplication
⎟ divide Alt-+ division
pi times a value or trigonometric
± pi and trigonometry Alt-o
functions
♠ diamond Alt-` join two expressions on the same line
↓ minus Alt-2 negative values
∗ power or exponential * raise a value or e to a power
∝ logarithm Alt-Shift-8 calculate a logarithm
minimum or floor Alt-d round down or find smaller of
maximum or ceiling Alt-s round up or find larger of
upgrade Alt-Shift-4 arrange values in ascending order
downgrade Alt-Shift-3 arrange values in descending order

METSIM OUTPUTS - MASS BALANCE, ENERGY BALANCE AND ENGINEERING

SPECIFICATIONS

Looking again at the simple flowsheet shown in figure 1 and comparing that to figure 6, the mass
balance may be seen in the table at the bottom of the diagram. The mass balance includes all components
and elements in the model. Mass balance checks can be performed on the entire model or a single section
of the model. Mass balances can be displayed in the model as tables either on the stream, as seen on stream
1 and 7 in figure 6, or at the bottom of the section as shown. Mass balance data can also be exported to
Excel by copy and paste or via dynamic data exchange (DDE) at the end of the calculation of the model.
The mass balance data can include any number of standard data items already available in METSIM or the
user can create custom items to display any piece of data they need. The level of complexity in data export
is again at the user’s discretion.

Energy balances may also be generated, displayed and exported to Excel. Energy balances include
stream heat content, heat of reaction, heat of solution, energy inputs, energy losses and energy required to
maintain specified output stream conditions. Heat of reaction is calculated automatically based on the
thermodynamic data entered by the user for each component or from the large component database built
into METSIM.

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

Figure 6 - Simple Crushing Circuit Mass Balance

Engineering specifications for all unit operations and streams can also be generated and exported
to Excel. A sample of some of the engineering data corresponding to model shown in figure 6 is shown in
table 3. Along with mass balance data for operating and design conditions, METSIM can also generate
equipment tag numbers based on user specifications and engineering equipment lists containing equipment
description and design parameters ready to distribute to vendors or other engineering personnel. Pipe
sizing, particle size distributions, instrument lists and detailed and operating cost analysis can also be
calculated and displayed in engineering documents if the user desires.

Table 3 – METSIM Engineering Stream Specifications

Nominal Operating Operating Design Design Density

Stream Solids Time Solids Design Solids Solids Temp Solids
Number ST/HR Fraction ST/HR Factor ST/HR % C t/m3
1 600.00 0.750 800.00 1.250 1000.0 100.0 33.0 2.650
2 378.72 0.750 504.96 1.250 631.2 100.0 33.0 2.650
3 221.28 0.750 295.04 1.250 368.8 100.0 33.0 2.650
4 221.28 0.750 295.04 1.250 368.8 100.0 33.0 2.650
5 600.00 0.750 800.00 1.250 1000.0 100.0 33.0 2.650
6 600.00 0.900 666.67 1.250 833.3 100.0 33.0 2.650
7 600.00 0.500 1200.00 1.250 1500.0 100.0 33.0 2.650

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 COM 2014 - Conference of Metallurgists Proceedings ISBN: 978-1-926872-24-7

METSIM RECENT PROJECT – CASERONES VALLEY-FILL HEAP LEACH – COPIAPO,

CHILE

Beginning in mid-2013, METSIM engineers worked alongside engineers and metallurgists from
the Caserones Valley-Fill Heap Leach Project located near Copiapo, Chile. Mining and heap stacking
operations there started in July 1, 2012, approximately one year before the simulation model was
developed. The goal was first to accurately simulate what had occurred at the site over year 1, including
solutions flows and tenors, Cu recoveries and cathode production. Following this exercise, the model
would then be used to optimize future leaching operations and to serve as a production forecasting tool.
Figures 7 and 8 show the heap leach and electrowinning flowsheets from the Caserones model
respectively.

Figure 7 – Caserones Heap Leach Model – Heap Leach Section

Daily historical data for ore tons and grade along with heap construction contours were organized
in METSIM to accurately simulate daily heap inventories over time. Leach cycles per lift were included to
generate simulated raffinate and pregnant leach solution (PLS) flows to and from the heap (including initial
solution stacking during the first 6 months of operation). Furthermore, each copper bearing mineral
corresponded to column recovery data which was curve-fit in METSIM to generate reaction rates. These
rates were then used to determine the reaction chemistry taking place inside the heap. Combining these key
parameters, along with historical weather data, simulated solution tenors for copper were generated by the
model. The actual operating solution tenors and those generated by the METSIM model are shown in
figure 9 and 10, respectively, for comparison.

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Figure 8 – Caserones Heap Leach Model – Electrowinning Section

Figure 9 – Comparisons Of Simulated Cu Solution Tenors Versus Actual Cu Solution Tenors For
Raffinate.

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Figuure 10 – Compaarisons Of Sim

mulated Cu Soluution Tenors Versus
V Actual Cu
C Solution Teenors For PLS.

Also includ
ded in this moodel was the soolvent extractioon (SX) and electrowinning
e (EW) plant foor
the prroduction of co
opper cathode. Isotherms for both extractioon and strippinng (re-extractioon) were used to
t
simulaate extraction of copper thrrough the SX plant while actual
a EW celll parameters such as currennt
efficieency and workking amperage simulated the weight of totaal cathode prodduced daily. A comparison of o
the cuumulative actuaal cathode platted versus the METSIM sim mulated cathode production is i seen in figurre
11.

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Figure 11 – Comparison Of Actual Cu Cathode Production (yellow) Versus METSIM Simulated Cu

Cathode Production (green). Actual Data Stops At Day 360. METSIM Production Prediction Continues
Through Day 520.

Given the success of the heap leach simulation model, Caserones has since contracted METSIM
to dynamically simulate their copper concentrator, which is yet to start production, with further interest in
simulating the entire site dynamically including the mine block model and detailed contoured tailings
management facility.

CONCLUSION

METSIM is currently being used by over 600 companies including 2000 individuals worldwide to
model or simulate a wide variety of processes in an even wider range of industries. METSIM is able to
simulate mining operations from the ground to the tailings facilities dynamically from ground breaking to
closure in a single model. Various modules within METSIM allow the user to choose what they need for
their specific process. The level of detail in any model is dictated by the user and can be as simple as a
flowsheet and mass balance or as complex as the day to day dynamic operation of an entire mine, mill, and
tailings facility. With the use of APL there is no limit to what can be accomplished in METSIM.

ACKNOWLEDGMENTS

The authors wish to acknowledge Walter Orquera Ledezma of Minera Lumina Copper, Caserones Mine
Project, Copiapo, Chile, for permission to use the Caserones project METSIM model in this paper.

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