DPSIM / DPSIM Static Module Manual

DPSIM Static Module Manual

This manual is the main user guide for DPSIM Static Module, the public steady-state mineral process simulation environment for building flowsheets, configuring unit-operation models, running static simulations and reviewing engineering results.

DPSIM Static Module focuses on steady-state simulation. Dynamic simulation, process control, reliability events and time-based studies are DPSIM Full capabilities and are outside the scope of this manual.

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1. Overview

DPSIM Static Module represents a mineral processing circuit as a flowsheet. The flowsheet contains equipment, called unit operations, connected by streams. Each stream carries material information such as solids flowrate, water flowrate, particle-size distribution and component content. Each unit operation applies a mathematical model to transform one or more input streams into one or more output streams.

FlowsheetThe visual representation of the plant or circuit. It shows the order in which material moves through feeders, crushers, mills, classifiers, separators, dewatering units and final products.

StreamThe material connection between two units. Streams store input data for feeds and simulated data for calculated products.

Unit operationAn equipment item placed on the flowsheet. Examples include feeders, crushers, ball mills, screens, hydrocyclones, flotation cells, thickeners, filters, mixers and splitters.

ModelThe calculation method used by a unit operation. Model parameters control how the selected equipment transforms the incoming material.

The static simulator solves the steady-state material balance for the circuit. It does not describe how the plant changes second by second; instead, it calculates the operating point associated with the current feed data, model parameters and flowsheet connections.

2. First Launch and Project Files

After opening DPSIM Static Module, the main workspace appears with an example flowsheet loaded. This startup circuit is useful for learning the interface because it contains a realistic arrangement of mineral processing units, streams, recycles and product streams.

DPSIM Static Module workspace showing an example mineral processing flowsheet — The startup workspace shows the flowsheet canvas in the center and the stream/model inspector panels on the right.

Project file operations

Command	Purpose	Typical use
New	Starts a new flowsheet project.	Use when beginning a new study from an empty circuit.
Open	Loads an existing DPSIM project or circuit file.	Use to continue a saved study or open an example circuit.
Save	Saves the current project.	Use frequently while building or editing a circuit.
Save As	Saves a copy under a new file name.	Use before creating a scenario variant.
Autosave	Periodically stores recovery copies according to the selected interval.	Use to reduce the risk of losing edits during model building.

When comparing scenarios, keep a clear naming convention. For example, use separate files for base case, changed feed, changed screen setting or changed mill setting. This makes later engineering review much easier.

Project name

The project name is used in the workspace status and in reports. Keep it short, descriptive and tied to the simulation case being reviewed. For scenario work, include a case identifier such as base case, screen change, feed change or mill setting change.

3. Main Interface

The interface is organized around the flowsheet. Selecting an equipment item or stream changes the inspector panels, so most work happens by selecting an object and then editing or reviewing the corresponding data on the right side.

Workspace areas

Menu barProvides project, edit, settings, report and simulation commands.

ToolbarProvides quick access to project files, project setup, unit-operation palettes, static run, results sheet, display controls and layout controls.

Flowsheet canvasThe drawing area where units and streams are placed, selected, connected, moved and organized.

Stream data areaThe upper inspector panel for stream input data and simulated stream data.

Model parameter areaThe lower inspector panel for selected equipment parameters, calculated values and detailed model outputs.

Status areaShows project status, equipment/stream count, zoom and simulation progress messages.

Important toolbar and menu commands

Area	Command	What it does
Project	New, Open, Save, Save As	Manage flowsheet project files.
Project setup	Size distribution, Components	Edit the project particle-size mesh and component list.
Model palettes	Feed, Comminution, Classification, Concentration, Dewatering, Auxiliary	Add unit operations to the flowsheet.
Simulation	Run Static Simulation	Runs the steady-state calculation.
Results	Stream Results Sheet	Opens a spreadsheet-style result review window.
View	Zoom, grid, snap to grid, right panel, status bar	Controls how the flowsheet is displayed and edited.
Layout	Show labels, show flyouts, lock canvas, align tools	Controls visible stream/equipment labels and drawing layout behavior.

DPSIM Static Module main interface showing the flowsheet, stream graph and model parameters — The main interface combines the flowsheet canvas with stream inspection, graph series, stream summaries and model parameters.

Settings tabs

The Settings dialog collects display, flyout, run and autosave options. These settings do not replace model inputs; they control how the workspace is displayed, how much information is visible and how the static solver is allowed to run.

DPSIM Static Module settings dialog view tab — The Settings dialog controls view options such as grid display, snap to grid, inspector panel visibility, status bar visibility, grid size and zoom.

DPSIM Static Module settings dialog visuals tab — The Visuals tab controls canvas colors, equipment labels and stream line appearance.

DPSIM Static Module settings dialog flyouts tab — The Flyouts tab controls the small stream-information boxes shown on the flowsheet.

DPSIM Static Module settings dialog autosave tab — The Autosave tab controls automatic saving behavior and backup limits.

4. Project Setup

A project should be configured before detailed feed data and model parameters are entered. The two most important project-wide settings are the particle-size mesh and the component list.

Particle-size mesh

The particle-size mesh defines the size intervals used by stream granulometry and by size-dependent models. Enter the size classes in descending order and keep the final pan interval at zero. Once the mesh is set, all stream size distributions use the same interval structure.

DPSIM Static Module default stream size classes dialog — The Default Stream Size Classes dialog defines the project granulometry mesh in micrometers and millimeters. The size classes should be edited in descending order.

Changing the particle-size mesh after feed data has been entered can invalidate size-distribution tables and model inputs. Set the mesh early, then keep it stable while building the simulation case.

Components

Components represent the mineral, chemical or material constituents tracked through the flowsheet. They are used for grade, assay and component-by-size calculations. Use clear names that match the plant study basis, such as Fe, SiO2, Cu, valuable mineral, gangue or other project-specific components.

Setup item	Recommendation	Reason
Size intervals	Use the same mesh as laboratory or plant PSD data when possible.	Reduces interpolation and makes model calibration easier.
Pan interval	Keep the last interval at zero.	Represents material below the finest sieve size.
Component names	Use short and consistent names.	Improves readability in stream tables and reports.
Component order	Keep the list stable after entering data.	Avoids confusion when comparing component columns across streams.

Practical setup sequence

Define the project particle-size mesh.
Define the component list.
Add feed units and enter feed stream data.
Add unit operations and connect streams.
Configure model parameters.
Run the static simulation and review results.

5. Working with the Flowsheet

The flowsheet canvas is the main workspace for building a circuit. Unit operations are added from model palettes, positioned on the canvas and connected with streams.

Adding units

Use the toolbar model categories to add equipment. The available categories in the Static Module include Feed, Comminution, Classification, Concentration, Dewatering and Auxiliary. Each category contains models that are appropriate for steady-state simulation.

Category	Typical models	Purpose
Feed	Editable Product Stream Feed, Water Feed, Density Regulator, Component PSD Feeder	Introduce solids, water, size distribution and component information into the circuit.
Comminution	Crushers, ball mills, rod mills, vertical mills, HPGR and energy-based comminution models	Represent size reduction and associated power or product-size behavior.
Classification	Screens, hydrocyclones and partition models	Split material by size or component partition behavior.
Concentration	Flotation and component recovery models	Separate valuable and non-valuable material using grade/recovery behavior.
Dewatering	Static thickener and filter models	Adjust water content and solids concentration.
Auxiliary	Mixer, splitter, static stockpile and related support units	Combine, divide or terminate streams in the flowsheet.

Connecting streams

Streams connect output ports to input ports. A unit may have one or more input/output ports depending on the model. When a stream is connected, it becomes part of the calculation path used by the static solver.

Add the upstream and downstream units to the flowsheet.
Use the available ports to create a stream connection from the upstream output to the downstream input.
Adjust the stream path if the drawing needs a cleaner route.
Run the static simulation and confirm that the calculated stream appears in the result panels.

Layout tools

Zoom, grid display, snap to grid, label visibility, flyouts and canvas locking help keep the circuit readable. Use snap to grid and alignment tools when building a presentation-quality flowsheet. Use canvas lock when reviewing results to avoid accidental movement of equipment or streams.

6. Streams and Material Data

Streams carry the material state between unit operations. Feed streams usually contain user input data. Downstream streams are calculated by the simulator after a static run.

DPSIM Static Module with a stream selected and stream data tabs visible — Selecting a stream displays stream input or simulated data in the upper inspector panel.

Stream properties

Property	Description	How to use it
Solids flowrate	Dry solids mass flow through the stream.	Use for mass-balance checks and equipment loading.
Water flowrate	Water associated with the stream.	Use for water-balance review and pulp density checks.
Pulp/slurry flow	Total stream including solids and water.	Use when comparing hydraulic loading or slurry handling.
Percent solids	Solids concentration in the stream.	Use to confirm whether process streams are realistic for the equipment.
Particle-size distribution	Mass distribution across the project size mesh.	Use to compare feed, product and classification performance.
Components	Component grades or fractions, optionally by size class.	Use for grade/recovery and metallurgical balance review.

Input data versus simulated data

The input data tabs are used when the user must define a stream, especially feed streams. The simulated data tabs show calculated values after the static run. If a downstream stream has no simulated results, first check that the upstream data, model parameters and stream connections are complete.

Graph views

Stream graphs help compare size-distribution curves. Use them to check whether comminution, screening, hydrocyclone or partition behavior is producing a plausible product. If a graph appears blank, verify that the stream has simulated size-distribution data and that the graph series are visible.

DPSIM Static Module stream size distribution graph window — The stream size-distribution graph compares selected granulometry curves and can be used to inspect feed, product and intermediate streams.

7. Unit Operation Models

Every process unit on the flowsheet uses a model. The model converts input streams into output streams according to its parameters and calculation method. The manual explains how to configure and review models; the mathematical details are maintained in the DPSIM Models Reference.

DPSIM Static Module with equipment selected and model parameters visible — When equipment is selected, the lower inspector panel shows model parameters, calculated parameters and detailed output tabs.

Model panel tabs

Tab or area	Purpose	Review practice
Model parameters	User-controlled model inputs.	Check units, default values and calibration basis before running scenarios.
Calculated parameters	Values derived from user inputs or the current simulation.	Use to check intermediate calculations such as power, split or capacity-related values.
Detailed output	Model-specific calculated tables or diagnostics.	Use when reviewing why a unit produced a particular result.
Reports/export tabs	Model documentation, validation and calculation details where available.	Use for engineering review or for documenting assumptions.

Configuration examples

A comminution model typically needs parameters that describe the equipment size, operating condition, energy input or breakage behavior. A classification model typically needs parameters for cut size, efficiency or partition behavior. Auxiliary models such as mixers and splitters handle stream combination, stream division and flowsheet routing.

Use the Models Reference to check parameter definitions before interpreting results. The reference is also the best place to review equations and model-specific assumptions.

Equipment report views

The report preview windows provide text-based summaries of equipment configuration and calculated values. They are useful when checking whether a model is configured as expected or when copying model information into an engineering note.

DPSIM Static Module equipment list report preview — The Equipment List report summarizes the units present in the current flowsheet.

DPSIM Static Module equipment input data report preview — The Equipment Input Data report lists model input parameters and configuration values.

DPSIM Static Module equipment simulated data report preview — The Equipment Simulated Data report lists calculated equipment outputs after a static run.

8. Static Simulation Workflow

The static simulation solves the current flowsheet using the project setup, stream input data and model parameters. The run command is available from the toolbar and the Simulation menu.

DPSIM Static Module showing a static simulation running on the example circuit — During a static run, DPSIM displays simulation progress while solving the flowsheet.

Pre-run checklist

The particle-size mesh and component list are defined.
Feed streams contain solids, water, size distribution and component data as required.
All intended equipment is connected by streams.
Each unit operation has a suitable model and realistic parameter values.
Recycle or split/mix structures are connected intentionally.
Static simulation iteration count is appropriate for the circuit complexity.

Iteration settings

The Static Simulation Iterations setting controls how many calculation passes the solver may perform. Simple circuits may solve quickly with a small number of iterations. Circuits with recycles or stronger interdependencies may need a larger limit, such as 100 or 1000 iterations.

DPSIM Static Module settings dialog showing static simulation iterations — The Settings dialog includes the Static simulation iterations control used by the static solver.

After the run

After a successful run, inspect the stream data, equipment calculated parameters and Results Sheet. If results look wrong, review the feed data first, then the connections, then the model parameters.

9. Results and Engineering Review

Result review should combine stream checks, equipment checks and overall mass-balance checks. Do not rely on only one stream or one graph when judging a flowsheet.

Stream Results Sheet

The Stream Results Sheet is a spreadsheet-style review window. It can load stream results, run the static simulation and load results, export CSV, copy data to the clipboard, select all, clear the grid and customize displayed lines and columns.

DPSIM Static Module Results Sheet with stream simulation outputs — The Results Sheet provides a compact view for comparing multiple streams and calculated properties.

Results Sheet feature	Use
Refresh	Reloads values from the current simulation state.
Run Static + Load	Runs the static simulation and then loads the updated stream values.
Export CSV	Exports the current grid for external review or reporting.
Copy to Clipboard	Copies selected result data for quick transfer into documents or spreadsheets.
Line tools	Add, insert, remove or load all streams as result lines.
Column tools	Add, insert, remove or configure output columns.
Stream Definition	Shows identifying information for the streams in the table.

Engineering checks

Mass balanceCompare total solids entering and leaving major process sections.

Water balanceCheck whether water addition, removal and stream percent solids are consistent.

Size distributionCompare feed and product curves around crushers, mills and classifiers.

Component gradesReview valuable and gangue component movement through concentration and classification stages.

10. Reports and Exporting

DPSIM Static Module includes several export and reporting paths. Use them according to the type of engineering review being prepared.

DPSIM Static Module report menu showing static run and data report options — The Report menu opens the static run report, equipment list, stream data, unit input data, unit full data and combined report outputs.

Output	Where it is used	Typical content
Export Image	Project or flowsheet menu.	Flowsheet image for presentations and reports.
Export Stream Data	Project/report commands and Results Sheet.	Stream values, simulated data and tabular stream comparisons.
Export Unit Data	Project/report commands.	Equipment model parameters, calculated data and unit-level information.
Static Run Report	Report menu.	Markdown-style summary of the static simulation case.
Equipment List	Report menu.	List of unit operations in the flowsheet.
Equipment Input Data	Report menu.	Model input parameters and user-defined equipment settings.
Equipment Simulated Data	Report menu.	Calculated unit-level outputs from the latest static simulation.
Detailed Stream Data	Report menu.	More complete stream-by-stream data for review.
Global Sheet Stream Data	Report menu.	Spreadsheet-style stream data summary.
All Report Data	Report menu.	Combined report package containing available report sections.

DPSIM Static Module static run report preview window — The Static Run Report preview provides a text report with refresh, copy and export commands for engineering documentation.

DPSIM Static Module detailed stream data report preview — The Detailed Stream Data report provides size-by-size and component data for selected streams.

For formal engineering communication, pair exported data with a short written basis: feed assumptions, size mesh, component list, model choices, calibration notes and scenario name.

11. Example Tutorial Using the Startup Circuit

The startup circuit can be used as a first guided example. The values are illustrative and should be calibrated before any real project decision, but the circuit is useful for understanding how data moves through DPSIM.

Open DPSIM Static Module and review the startup flowsheet.
Identify the feed units, comminution section, classification section, recirculating streams and final product streams.
Select a feed stream and review solids flow, water flow, size distribution and component data.
Select a crusher or mill and review the model parameters.
Select a screen, hydrocyclone or partition unit and review classification parameters.
Run the static simulation.
Open the Stream Results Sheet and load all streams.
Compare the main feed, circulating load, product and tailings streams.
Check whether the product size distribution and component grades are plausible for the intended example.
Save a copy before changing parameters for scenario comparison.

After this walkthrough, a useful exercise is to change one operating parameter at a time, rerun the static simulation and compare the Results Sheet. This helps build intuition for how model parameters affect the circuit balance.

12. Troubleshooting and Best Practices

Symptom	Likely cause	Action
No result appears for a stream.	The stream is not connected, the upstream unit has missing data, or the simulation has not been run.	Check connections, feed data and model parameters, then rerun the static simulation.
Size-distribution graph is blank.	The stream has no simulated granulometry or graph series visibility is not enabled.	Select the relevant stream, confirm simulated size data exists and review graph series settings.
Results look physically unrealistic.	Feed data, water data, component data or model parameters may be inconsistent.	Start from feed streams and work downstream, checking one unit at a time.
Circuit is hard to read.	Equipment and streams are not aligned or labels/flyouts are cluttered.	Use grid, snap to grid, zoom, label visibility and alignment tools.
Changing project mesh caused data loss.	Project mesh changes affect all streams.	Set mesh before detailed data entry and save a backup before changing it.
Simulation does not stabilize as expected.	Recycle structure or model settings may require more iterations or better initial data.	Increase static iteration count and inspect recycle-connected units for unrealistic parameters.

Best practices

Keep project files organized by scenario.
Use clear stream and equipment names.
Document assumptions outside the model when preparing engineering deliverables.
Review both stream-level and unit-level results.
Use the Models Reference whenever a parameter meaning is not obvious.

13. Static Module Boundaries

DPSIM Static Module includes the public steady-state workflow: flowsheet building, stream definition, unit-operation model configuration, static simulation, stream/equipment result review and data export. It is intended for static mineral process simulation and model review.

DPSIM Full extends the platform into dynamic simulation, process control, reliability analysis, maintenance events, time-based plant behavior and advanced project-specific workflows. Those capabilities are described elsewhere on the DPSIM website and can be discussed through EPM for consulting or project deployment.

View Models Reference Download DPSIM Static Module Contact EPM