void FilterPress::EvalProducts()
{
try {
int idPressNote = 0, idWashNote = 1;
MStreamI QFeed;
FlwIOs.AddMixtureIn_Id(QFeed, idFeed);
const double dFeedSolidMass = QFeed.Mass(MP_Sol);
const double dFeedLiquidMass = QFeed.Mass(MP_Liq);
MStreamI QWashWater;
const bool bWashWaterConnected = (FlwIOs.getCount(idWash) > 0);
if (bWashWaterConnected)
FlwIOs.AddMixtureIn_Id(QWashWater, idWash);
//MStream QUnwashedCake = QFeed; BAD idea, QUnwashedCake becomes a reference to QFeed!!!!
MStreamI QUnwashedCake;
QUnwashedCake = QFeed;
QUnwashedCake.ZeroMass();
MStream& QFiltrate = FlwIOs[FlwIOs.First[idFiltrate]].Stream;
QFiltrate = QFeed;
MStream& QCake = FlwIOs[FlwIOs.First[idCake]].Stream;
QCake = QFeed;
const bool bWashingsConnected = (FlwIOs.Count[idWashings] > 0);
//First off: The filtrate & UnwashedCake:
/*Equations Solved using Mathematica 6.0, under the constrainsts of:
- Conservation of mass
- Cake Moisture Content
- Filtrate Solid Concentration [Either in % or g/L]
- When using g/L, assume solid and liquid densities don't change [The (Aq) conc's don't]
*/
double dSolConcConstFac, dLiqConcConstFac;
bool bTooWet;
switch (eFiltrateMethod) {
case FM_SolidsToFiltrateFrac:
dSolConcConstFac = dReqSolidsToFiltrate;
dLiqConcConstFac = dReqSolidsToFiltrate;
bTooWet = dFeedSolidMass / NZ(dFeedSolidMass + dFeedLiquidMass) < dReqSolidsToFiltrate;
break;
case FM_FiltrateConc:
dSolConcConstFac = dReqFiltSolConc / QFeed.Density(MP_Sol, C_2_K(25));
dLiqConcConstFac= dReqFiltSolConc / QFeed.Density(MP_Liq, C_2_K(25));
bTooWet = dFeedSolidMass / NZ(QFeed.Volume(MP_SL, C_2_K(25))) < dReqFiltSolConc;
break;
}
/*Situations where variables can be out of range:
- Mass comes in too wet - required loss causes all mass to be sent to filtrate
- Mass comes in too dry - mass is drier than required moisture frac.
*/
double dFiltSolidFactor, dFiltLiquidFactor, dCakeSolidFactor, dCakeLiquidFactor;
if (bTooWet)
{
SetNote(idPressNote, "Input feed too wet: All feed solids sent to filtrate");
dFiltSolidFactor = dFiltLiquidFactor = 1;
dCakeSolidFactor = dCakeLiquidFactor = 0;
}
else if (dFeedLiquidMass / NZ(dFeedSolidMass + dFeedLiquidMass) < dReqCakeMoisture)
{
SetNote(idPressNote, "Input feed too dry: All feed liquids sent to Cake");
dFiltSolidFactor = dFiltLiquidFactor = 0;
dCakeSolidFactor = dCakeLiquidFactor = 1;
}
else
{
dFiltSolidFactor = (((dFeedLiquidMass * (dReqCakeMoisture - 1) + dFeedSolidMass * dReqCakeMoisture) * dLiqConcConstFac)
/ NZ(dReqCakeMoisture * dLiqConcConstFac - (dReqCakeMoisture - 1)*(dSolConcConstFac-1))) / dFeedSolidMass;
dFiltLiquidFactor = - (((dFeedLiquidMass * (dReqCakeMoisture - 1) + dFeedSolidMass * dReqCakeMoisture) * (dSolConcConstFac - 1))
/ NZ(dReqCakeMoisture * dLiqConcConstFac - (dReqCakeMoisture - 1)*(dSolConcConstFac - 1))) / dFeedLiquidMass;
dCakeSolidFactor = 1 - dFiltSolidFactor;
dCakeLiquidFactor = 1 - dFiltLiquidFactor;
}
for (int i = 0; i < gs_MVDefn.Count(); i++)
if (gs_MVDefn[i].IsSolid())
{
QFiltrate.M[i] = QFeed.M[i] * dFiltSolidFactor;
QUnwashedCake.M[i] = QFeed.M[i] * dCakeSolidFactor;
}
else if (gs_MVDefn[i].IsLiquid())
{
QFiltrate.M[i] = QFeed.M[i] * dFiltLiquidFactor;
QUnwashedCake.M[i] = QFeed.M[i] * dCakeLiquidFactor;
}
//Now, wash it:
//First, add the washwater solids, and record what mass of solids we add.
//The equations associated with this are exceedingly ugly.
if (FlwIOs.getCount(idWash) > 0) {
//Short variables to create fewer errors translating the equations
double WS = QWashWater.Mass(MP_Sol);
double WL = QWashWater.Mass(MP_Liq);
double CS = QUnwashedCake.Mass(MP_Sol);
double CL = QUnwashedCake.Mass(MP_Liq);
double a, rWS, rWL, rCS, rCL;
double m = dReqCakeMoisture;
double w;
switch (eWashMethod)
{
case WM_ConstantEfficiency:
w = dReqWashEfficiency;
case WM_WashRatio:
dWashRatio = WL / NZ(CL);
w = 1 - pow(1-dReqWashEfficiency, dWashRatio);
}
switch (eFiltrateMethod) {
case FM_SolidsToFiltrateFrac:
a = dReqSolidsToFiltrate;
rWS = rWL = rCS = rCL = 1;
break;
case FM_FiltrateConc:
a = dReqFiltSolConc;
rWS = QWashWater.Density(MP_Sol, C_2_K(25));
rWL = QWashWater.Density(MP_Liq, C_2_K(25));
rCS = QUnwashedCake.Density(MP_Sol, C_2_K(25));
rCL = QUnwashedCake.Density(MP_Liq, C_2_K(25));
break;
}
/*Possible situations where variables are out of range:
- A: Too much wash liquid - all solids are sent out in washings ['Fix' by sending everyhing to washings. Assume we will not end up with only washing solids]
- B: Not enough wash liquid - required wash efficiency impossible ['Fix' by putting all wash water in cake]
- C: Cake comes in dry [And very dry] - wash efficiency is higher than requested even if no cake moisture is displaced.
[Fix by sending everything].
- D: Wash water has FAAR too many solids - cake moisture is lower than required. [Fix by putting everything into cake]
- Cake should never come in too wet.
*/
//CO - Cake Out. WO - Washings out.
double dCLtoCO, dCStoCO, dWStoCO;
double dTemp = (WS*rCL*rCS*rWL*(a-rWS)+(a*WL*rCL*rCS+(CS*rCL*(a-rCS)+a*CL*rCS)*rWL)*rWS)
/ NZ(CS*(m*a*(1-w)*rCS*rWL+rCL*((1-m)*a*rWL+rCS*(m*a*w-(1-m)*rWL)))*rWS + WS*rCL*rCS*((1-m)*rWL*(a-rWS)+m*a*rWS));
double dWLtoCO = m * (w*CS + WS) * dTemp;
if (dWLtoCO > WL)
{ //Case B - not enough wash liquid
SetNote(idWashNote, "Not enough wash water: All wash water sent to cake");
//double dTemp1 = (WS*rCL*rCS*(a-rWS)+(CS*rCL*(a-rCS)+a*CL*rCS)*rWS)
// / NZ(CS*((1-m)*rCL*(a-rCS)+m*a*rCS)*rWS + WS*rCS*((1-m)*rCL*(a-rWS) + m*a*rWS));
double dTemp1 = 1 / (CS * ((1-m) * rCL * (a-rCS) + m*a*rCS) * rWS + WS * rCS * ((1-m) * rCL * (a-rWS) + m*a*rWS));
double dTemp2 = WS * rCL * rCS * (a-rWS) + (CS * rCL * (a-rCS) + a*(CL+WL)*rCS)*rWS;
dWLtoCO = WL;
dCLtoCO = (m*CS*CS*rCL*(a-rCS)*rWS + CS*((-(1-m)*WL*rCL*(a-rCS) + m*a*CL*rCS)*rWS+m*WS*rCL*(rCS*(a-2*rWS)+a*rWS))
+ WS*rCS*(-(1-m)*WL*rCL*(a-rWS) + m*(WS*rCL*(a-rWS) + a*CL*rWS))) * dTemp1;
dCStoCO = (1-m) * CS * dTemp1 * dTemp2;
dWStoCO = (1-m) * WS * dTemp1 * dTemp2;
}
else
{
//dWLtoCO already set.
dCLtoCO = m * (1-w) * CS * dTemp;
dCStoCO = (1-m) * CS * dTemp;
dWStoCO = (1-m) * WS * dTemp;
}
if (dCLtoCO > CL) { //Case C - not enough cake moisture [Can only happen if cake comes in with moisture content v. low.]
dCLtoCO = CL; //Although this results in a lower than required moisture content, well, the cake is comming in drier than required.
SetNote(idWashNote, "Cake too dry"); }
//Simple Cons of Mass:
double dWLtoWO = WL - dWLtoCO;
double dCLtoWO = CL - dCLtoCO;
double dWStoWO = WS - dWStoCO;
double dCStoWO = CS - dCStoCO;
double dWLtoCOFrac,dCLtoCOFrac,dWStoCOFrac,dCStoCOFrac,dWLtoWOFrac,dCLtoWOFrac,dWStoWOFrac,dCStoWOFrac;
if (dCStoCO < 0) //Case A, Too wet: Everything sent with washings
{
SetNote(idWashNote, "Too much liquid in WashWater. Everything sent to washings");
dWLtoCOFrac=dCLtoCOFrac=dWStoCOFrac=dCStoCOFrac=0;
dWLtoWOFrac=dCLtoWOFrac=dWStoWOFrac=dCStoWOFrac=1;
}
else if ((CL+WL)/NZ(CS+WS+CL+WL) < m) //Case D, Too Dry: Send everything to cake.
{
SetNote(idWashNote, "Not enough liquid in washing stage. Everything sent to cake");
dWLtoCOFrac=dCLtoCOFrac=dWStoCOFrac=dCStoCOFrac=1;
dWLtoWOFrac=dCLtoWOFrac=dWStoWOFrac=dCStoWOFrac=0;
}
else
{
//Here's where we handle if we have any other zeros.
//Also handle if a variable manages to slip by the other checks [It is possible with outlandish input parameters.]
dWLtoCOFrac = WL > 0 ? dWLtoCO / WL : 0;
dCLtoCOFrac = CL > 0 ? dCLtoCO / CL : 0;
dWStoCOFrac = WS > 0 ? dWStoCO / WS : 0;
dCStoCOFrac = CS > 0 ? dCStoCO / CS : 0;
dWLtoWOFrac = WL > 0 ? dWLtoWO / WL : 0;
dCLtoWOFrac = CL > 0 ? dCLtoWO / CL : 0;
dWStoWOFrac = WS > 0 ? dWStoWO / WS : 0;
dCStoWOFrac = CS > 0 ? dCStoWO / CS : 0;
}
dWashEfficiency = CL > 0 ? 1 - dCLtoCOFrac : dNAN;
//MStream QWashingOutput = QCake; BAD idea, QWashingOutput becomes a reference to QCake!!!!
MStreamI QWashingOutput;
QWashingOutput = QCake;
QWashingOutput.ZeroMass();
for (int i = 0; i < gs_MVDefn.Count(); i++)
if (gs_MVDefn[i].IsSolid())
{
QWashingOutput.M[i] = QUnwashedCake.M[i] * dCStoWOFrac + QWashWater.M[i] * dWStoWOFrac;
QCake.M[i] = QUnwashedCake.M[i] * dCStoCOFrac + QWashWater.M[i] * dWStoCOFrac;
}
else if (gs_MVDefn[i].IsLiquid())
{
QWashingOutput.M[i] = QUnwashedCake.M[i] * dCLtoWOFrac + QWashWater.M[i] * dWLtoWOFrac;
QCake.M[i] = QUnwashedCake.M[i] * dCLtoCOFrac + QWashWater.M[i] * dWLtoCOFrac;
}
double dInputHf;
MStream* pQWashingOutput;
if (bWashingsConnected) //bWashingsConnected indicates whether OUTPUT washings are connected.
{
dInputHf = QUnwashedCake.totHf() + QWashWater.totHf();
pQWashingOutput = &QWashingOutput;
}
else
{
dInputHf = QUnwashedCake.totHf() + QWashWater.totHf() + QFiltrate.totHf();
for (int i = 0; i < gs_MVDefn.Count(); i++)
QFiltrate.M[i] += QWashingOutput.M[i];
pQWashingOutput = &QFiltrate; //For thermal property managing
}
double dgbTi = pQWashingOutput->T;
bool converged = false;
for (int i = 0; i < 10 && !converged; i++)
{
double dbgTt = pQWashingOutput->T;
double dOutputHf = QCake.totHf() + pQWashingOutput->totHf();
double deltaT = -(dOutputHf - dInputHf) / NZ(pQWashingOutput->totCp() + QCake.totCp());
pQWashingOutput->T += deltaT;
QCake.T = pQWashingOutput->T;
converged = abs(dInputHf - dOutputHf) < 1; //TODO: Check what sort of convergence we require.
}
double dbgT = pQWashingOutput->T;
double dbgT2 = QWashingOutput.T;
if (bWashingsConnected)
{
MStream& QWashings = FlwIOs[FlwIOs.First[idWashings]].Stream;
QWashings = QWashingOutput;
}
}
else //If we have no washings
{
if (bWashingsConnected)
{
MStream& QWashings = FlwIOs[FlwIOs.First[idWashings]].Stream;
QWashings.ZeroMass();
}
QCake = QUnwashedCake;
}
//Vent:
if (FlwIOs.Count[idVent] > 0)
{
MStream& QVent = FlwIOs[FlwIOs.First[idVent]].Stream;
QVent = QCake;
QVent.ZeroMass();
MStreamI QWashWater;
if (FlwIOs.Count[idWash] > 0)
QWashWater = FlwIOs[FlwIOs.First[idWash]].Stream;
else
QWashWater.ZeroMass();
for (int i = 0; i < gs_MVDefn.Count(); i++)
if (gs_MVDefn[i].IsGas())
QVent.M[i] = QCake.M[i] + QWashWater.M[i];
}
//Update "Actual" values.
dCakeSolids = QCake.MassFrac(MP_Sol);
dFiltSolids = QFiltrate.MassFrac(MP_Sol);
dCakeSolConc = QCake.Mass(MP_Sol) / NZ(QCake.Volume(MP_All, C_2_K(25.0)));
dFiltSolConc = QFiltrate.Mass(MP_Sol) / NZ(QFiltrate.Volume(MP_All, C_2_K(25.0)));
if (bWashWaterConnected)
{
double CFeed = QFeed.SpecieConc(MP_Liq, nWashCompSpecie, C_2_K(25.0));
double CCake = QCake.SpecieConc(MP_Liq, nWashCompSpecie, C_2_K(25.0));
double CWash = QWashWater.SpecieConc(MP_Liq, nWashCompSpecie, C_2_K(25.0));
dWashCompEff = (CFeed - CCake) / NZ(CFeed - CWash);
}
else
{
dWashCompEff = 0;
dWashEfficiency = 0;
}
}
catch (MMdlException &e)
{
Log.Message(MMsg_Error, e.Description);
}
catch (MFPPException &e)
{
e.ClearFPP();
Log.Message(MMsg_Error, e.Description);
}
catch (MSysException &e)
{
Log.Message(MMsg_Error, e.Description);
}
catch (...)
{
Log.Message(MMsg_Error, "Some Unknown Exception occured");
}
}
void FlotationCell::EvalProducts()
{
try
{
dPrimaryRecovery = dReqPrimaryRecovery;
dPrimaryGrade = dReqPrimaryGrade;
for (unsigned int i = 0; i < vSecondaryRecoveries.size(); i++)
vSecondaryRecoveries.at(i) = vReqSecondaryRecoveries.at(i);
//sum all input streams into a working copy
MStreamI QI;
FlwIOs.AddMixtureIn_Id(QI, idFeed);
MStreamI QAir;
FlwIOs.AddMixtureIn_Id(QAir, idAir);
bool bAirOn = FlwIOs.Count[idAir] > 0;
//get handles to output streams...
MStream & QOT = FlwIOs[FlwIOs.First[idTail]].Stream;
MStream & QOC = FlwIOs[FlwIOs.First[idConc]].Stream;
MStream & QOV = FlwIOs[FlwIOs.First[idVent]].Stream;
QOT = QI;
QOT.ZeroMass();
QOC = QI;
QOC.ZeroMass();
if (!m_bOn)
{
QOT = QI;
QOV = QAir;
dPrimaryRecovery = dPrimaryGrade = 0;
for (vector<double>::iterator it = vSecondaryRecoveries.begin(); it != vSecondaryRecoveries.end(); it++)
*it = 0.0;
return;
}
if (QI.Mass(MP_Sol) > QI.Mass(MP_Liq))
Log.SetCondition(true, LC_BadInput, MMsg_Warning, "Input stream contains more solid than liquid.");
if (bAirOn && (QAir.Mass(MP_Sol) > UsableMass || QAir.Mass(MP_Liq) > UsableMass))
Log.SetCondition(true, LC_BadAir, MMsg_Warning, "Air stream contains liquids or solids");
if (bAirOn && QAir.Volume(MP_Gas) < 2 * QI.Volume(MP_Sol))
Log.SetCondition(true, LC_LittleAir, MMsg_Warning, "Air stream contains very little gas");
QI.AddF(QAir, MP_All, 1);
//do the work...
const int NumSpecies = gs_MVDefn.Count();
//Primaries:
double dPrimaryMassConc = 0.0;
double dPrimaryElementConc = 0.0;
for (unsigned int i = 0; i < vPrimaryIndices.size(); i++)
{
double temp = QI.M[vPrimaryIndices.at(i)];
dPrimaryMassConc += temp * dReqPrimaryRecovery;
if (eSpecType == FTST_ByElement)
dPrimaryElementConc += temp * dPrimaryRecovery * ElementMassFrac(vPrimaryIndices.at(i), nPrimary1);
else
dPrimaryElementConc += temp * dPrimaryRecovery;
QOT.M[vPrimaryIndices.at(i)] = temp * (1 - dReqPrimaryRecovery);
QOC.M[vPrimaryIndices.at(i)] = temp * dReqPrimaryRecovery;
}
if (dPrimaryElementConc == 0)
{
dPrimaryRecovery = dNAN;
Log.SetCondition(true, LC_NoPrimaries, MMsg_Warning, "No primary compounds found in feed.");
}
//Secondaries:
double dSecondaryMassConc = 0.0;
for (unsigned int i = 0; i < vSecondaryIndices.size(); i++)
{
double temp = QI.M[vSecondaryIndices.at(i)];
dSecondaryMassConc += temp * vReqSecondaryRecoveries.at(i);
QOT.M[vSecondaryIndices.at(i)] = temp * (1 - vReqSecondaryRecoveries.at(i));
QOC.M[vSecondaryIndices.at(i)] = temp * vReqSecondaryRecoveries.at(i);
if (eSpecType == FTST_ByElement)
dPrimaryElementConc += temp * vReqSecondaryRecoveries.at(i) * ElementMassFrac(vSecondaryIndices.at(i), nPrimary1);
}
//Those not included in either primaries or secondaries.
double dPrimaryElementInGangue = 0;
double dOtherMassIn = 0.0;
for (unsigned int i = 0; i < vOtherIndices.size(); i++)
{
dOtherMassIn += QI.M[vOtherIndices.at(i)];
if (eSpecType == FTST_ByElement)
dPrimaryElementInGangue += QI.M[vOtherIndices.at(i)] * ElementMassFrac(vOtherIndices.at(i), nPrimary1);
}
double dPrimaryGangueFrac = dPrimaryElementInGangue / NZ(dOtherMassIn);
double dReqOtherMassOut = (dPrimaryElementConc - dReqPrimaryGrade * (dPrimaryMassConc + dSecondaryMassConc)) / NZ(dReqPrimaryGrade - dPrimaryGangueFrac);
if (dReqOtherMassOut < 0) //If this is the case, we will put in no more impurities.
{
if (dPrimaryElementConc / QOC.Mass(MP_Sol) < dReqPrimaryGrade)
{
Log.SetCondition(true, LC_NoGrade, MMsg_Warning, "Secondary products prevent required primary grade");
dReqOtherMassOut = 0;
}
else
{
Log.SetCondition(true, LC_NoGrade, MMsg_Warning, "Grade of gangue to concentrate higher than required grade");
if (dPrimaryElementConc / QOC.Mass(MP_Sol) > dPrimaryGangueFrac) //We will get as close as possible...
dReqOtherMassOut = dOtherMassIn;
}
}
if (dReqOtherMassOut > dOtherMassIn)
{
Log.SetCondition(true, LC_NoGrade, MMsg_Warning, "Not enough unspecified input mass to achieve required primary grade");
dReqOtherMassOut = dOtherMassIn;
}
for (unsigned int i = 0; i < vOtherIndices.size(); i++)
{
QOC.M[vOtherIndices.at(i)] = QI.M[vOtherIndices.at(i)] * dReqOtherMassOut / NZ(dOtherMassIn);
QOT.M[vOtherIndices.at(i)] = QI.M[vOtherIndices.at(i)] * (1 - dReqOtherMassOut / NZ(dOtherMassIn));
}
dPrimaryElementConc += dReqOtherMassOut * dPrimaryGangueFrac;
//Finally: We deal with non-solid species:
/*for (int i = 0; i < gs_MVDefn.Count(); i++)
{
if (gs_MVDefn[i].IsSolid())
continue;
QOC.M[i] = QI.M[i] * dReqWaterFrac;
QOT.M[i] = QI.M[i] * (1 - dReqWaterFrac);
}*/
QOC.AddM(QI, MP_Liq, QI.Mass(MP_Liq) * dReqWaterFrac);
QOT.AddM(QI, MP_Liq, QI.Mass(MP_Liq) * (1 - dReqWaterFrac));
if (FlwIOs.Count[idVent] > 0)
{
QOV = QI;
QOV.ZeroMass();
QOV.AddM(QI, MP_Gas, QI.Mass(MP_Gas));
}
else
{
QOC.AddM(QI, MP_Gas, QI.Mass(MP_Gas));
if (FlwIOs.Count[idAir] > 0)
Log.SetCondition(true, LC_Vent, MMsg_Warning, "Stream connected to air, but no stream connected to vent.");
}
if (QOC.Mass(MP_Sol) > 0)
dPrimaryGrade = dPrimaryElementConc / NZ(QOC.Mass(MP_Sol));
else
dPrimaryGrade = dNAN;
dSfConcentrate = QOC.MassFrac(MP_Sol);
dSfTailings = QOT.MassFrac(MP_Sol);
}
catch (MMdlException &e)
{
Log.Message(MMsg_Error, e.Description);
}
catch (MFPPException &e)
{
e.ClearFPP();
Log.Message(MMsg_Error, e.Description);
}
catch (MSysException &e)
{
Log.Message(MMsg_Error, e.Description);
}
catch (...)
{
Log.Message(MMsg_Error, "Some Unknown Exception occured");
}
}
