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Material balancing-a
method
R. I. Mackie
Minerals
and Metals
Division,
Warren
Spring
Laboratory,
Stevenage,
Herts,
UK
A method for the solution of material balancing problems encountered in mineral processing is described. The method makes use of the highly structured nature of the equations encountered, thus
resulting in savings in computer storage space and computation time. One of the key advantages of
the method is that it is presented in a very general way and can therefore be used to solve a wide
variety of balancing problems. In particular, the method enables constraints imposed upon individual
streams (e.g., sum of size distribution must equal 100%) to be handled at very little extra cost, whereas
most other balances tend not to deal with these sorts of constraints.
Keywords:
Introduction
A mineral treatment plant can consist of many interconnected unit processes, and in order to operate the
plant efficiently it is necessary to have an accurate
picture of what is happening at all parts of the circuit.
However, data collection is an expensive task, and the
raw data will be contradictory; e.g., the measured mass
flow entering the circuit will not equal the measured
mass flow leaving the circuit. Therefore the data have
to be balanced in order to produce data that are consistent. This is a task which lends itself readily to computer methods, and programs to do this have been
available for many years. The first material balances
were written for mainframe computers, and a useful
review can be found in Reid et al. With the advent of
microcomputers these methods are now readily available to the plant engineer, and Warren Spring Laboratory (WSL) has produced balance programs for use
on microcomputers.*
However, the microcomputer
balances shared the common problem of limitations on
the problem size that can be dealt with. There are also
potentially many sorts of balances that can be carried
out, ranging from balancing only the total mass flow
to balancing total mass flow, pulp density, size/specific
gravity (SG) distribution, and assay data. This paper
describes a method that breaks down the problem into
smaller components, thereby reducing the storage space
needed, reducing the time of computation and providing the framework for a much more general solution
process.
E = 5
WU(xti - x8)
i=l
(1) stream constraints; e.g., the sum of the size distribution must equal 100%; the sum of the size
assays must equal the total assay.
(2) nodal constraints; i.e., the total mass of each com-
0 1989 Butterworth
Publishers
of Civil Engineering,
149
Material
balancing-a
generalized
solution method:
R. I. Mackie
Stream 1 data
Stream n data
Stream constraints
1 Lagrange
multipliers
(Z3 (;)=(i)
Figure 1.
nodes
(3)
PX = B
(4)
Therefore
X = D-(A
Substituting
- PY)
(5)
(PD-P)Y
= PD-A
- B
(7)
D,
where Di is the matrix associated
the structure
Math. Modelling,
El
, p3
Appl.
(6)
Equation structure
150
(2)
Figure 2.
Flowsheet as independent
paths
Material
Li
i
Mi
balancing-a
generalized
solution method:
R. I. Mackie
(8)
L, Mr,
(15)
where Li is the matrix associated with the stream Lagrange multipliers for stream i, and M, is the nodal
Lagrange multiplier matrix associated with stream i.
X can be written as
X=(Xi,...,X#
(9)
stream variables
(10)
(11)
where Ai is associated
(12)
where Bj is associated with the stream Lagrange multipliers for stream i, and BZ with the nodal Lagrange
multipliers.
Using this decomposition, we can write the left side
of equation (6) as
PD-P
f...
. . . Lk)r...
M;...@
u;.**u:,
where
Vi = L:DD;Li
Ui = LID; M;
W = EMIDiMi
(K, * . . 3 Yn, a*
= [;
as
D-
; )
Ui = LID;-Ai - Bi
b = EMiD; Ai - BZ
(16)
Vi Y; + UiZ = U;,
CU:Y/+
Therefore
WZ=b
(17)
(18)
Y, = v; (a; - U;Z)
(19)
and so
(W - Z U:V;Ui)Z
= b - ~ U:V;Ui
(20)
(1;)
=ir-.
..,3
L,,M,
L1D;
Al
LLD,
1
kf\D; . . . MLD,
L:D;
:I
Mi
.
L Mn
- LiYi - MiZ)
(22)
which gives
Xi = Di(Ai
LLD, M,
MrD;L, . . . M,D,L,
(21)
[ii All
L: D, M,
L:D, L,
CM:D; M;
Example
M~DD;
. . MLD,
(14)
151
Material
balancing-a
generalized
solution
method:
R. I. Mackie
Mi has the general form
(23)
s:
. ..s& o...o-s:
(24)
and d constraints
C Qi,_MiSy = 0
I
(25a)
+ x
(34)
Z = (Gii,. ** 9GNd)t
and A, B, and BZ by
Ai = 2 (WiM$ywiisz,.
. . ) Wins%)
(35)
(25b)
Bi = (1)
E = C
Wo(S; - Sf)
(26)
=
u
- MT) + x GLjQiLSt
(27)
Lj
(28)
$+j-l
.i
gj
QiL(Mis& + M:s,
M~s:)
(30)
(31)
(O,I,...,I)
152
are as follows:
1) +iGLj
$,
.o...o
-MY
. ..-s$
(32)
(36)
Material
balancing-a
generalized
solution method:
R. I. Mackie
Where total mass flow and size distribution are measured the problem size is as follows:
D,
= 1+ d
Numberofvariablesper
stream
Number of constraints per stream = 1
= d
Number of constraints per node
Therefore the total number of variables in the complete
system of equations is n*(l + d) + n + m*d, where
n is the number of streams and m the number of nodes.
For the partially reduced system in equation (4) the
number of variables is n + m*d and for the fully reduced system, m*d.
For a system with 4 size fractions, 27 nodes, and
54 streams, the complete system has 432 variables, the
partially reduced system 162, and the fully reduced
system 108. To obtain the size of matrix to be stored,
all these figures have to be squared, and this gives
186,624, 26,244, and 11,664, respectively. This highlights the saving made. Storage space is not the only
saving. The amount of work required to solve a set of
simultaneous linear equations is proportional to the
cube of the number of variables, so there is also a
considerable saving here as well. In the above example
using the partially reduced system, the time for one
iteration was 6.6 CPU seconds, whereas the new method
took 1.O CPU seconds (both times being on a MicroVAX
II computer). The saving is due to solving a smaller
set of equations, and the decomposition generally leads
to a more efficient program.
(37)
Tl
L,
(38)
PD-P
W = 2 M:D;Mi
+ x M;+,T;M,+,
If there are some constraints relating the transfer coefficients within each group, P will have exactly the same
form as in (8).
Conclusion
Combining
simulation
mass balancing
and flowsheet
The equations arising out of material balancing problems are of a highly structured form. A method has
been described that expresses the structure in a form
applicable to a wide variety of problems, and a general
solution scheme is presented using this structure. This
method results in a considerable saving in the storage
space required, and also in the computation time. Both
these savings are very significant in the writing of balancing software for microcomputers. Although the above
discussion has concentrated upon the fully linear problem, the nonlinear problem can usually be linearized
in such a way as to enable the above method to be
used.
The method makes full use of the structure of the
stream constraint part of the equations, but part of the
equation structure that has not been fully developed
is that of the matrices M (the nodal constraint matrices). Simpsons method, on the other hand, makes full
use of this structure. If the present method and Simpsons method could be combined, the result would be
an even more efficient method. (This is the key difference between the two methods.) The possibility of
doing this should be investigated.
Notation
d
D
153
Material
balancing-a
generalized
solution method:
M;, MI
:Jl
P
sij
w,w
x, x*
X
Y
number of nodes
number of streams
matrix associated with Lagrange multipliers
fraction in size interval j of stream i
weighting factors
adjusted and measured readings
vector of adjusted measurements
vector of Lagrange multipliers
R. I. Mackie
References
1
1976, 3, 207-218
Subscripts
i
stream number
size fraction
154