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Circulating Load Calculations

Screen Efficiency Factors

Circulating Load
- Amount of material deemed
insufficiently processed
• Considered for closed-circuit
comminution
– Wide particle size distribution

• Computed for:
– Equipment sizing
– Feed control

Problem #1
• Given:
– 100 Mt/h ROM feed
– Primary Gyratory Crusher
• Product particle size analysis:
– 70% - ½”
– 30% + ½”

– Single-deck Vibrating Screen
• ½” aperture
• Screen Efficiency: 100%

1 Pass: t = 1 hour
st

st

70% Undersize
30% Oversize
100% Efficiency

100 Mt

30%

10 GC

70%

Vib
ra t i

70 Mt –
½“

ng
Scr
een

-

+

30 Mt
+½“

Re-circulate
to GC!

3x30) = 39 Mt Re-circulate to GC! .7x30) = 91 Mt ng Scr een - + 30 + (0.2 Pass: t = 2 hour nd nd New feed: 70% Undersize 30% Oversize 100% Efficiency (100+30) =130 Mt 30% 10 GC 70% Vib ra t i 70 + (0.

70 Mt Re-circulate to GC! .3 Pass: t = 3 hour rd rd New feed: 70% Undersize 30% Oversize 100% Efficiency (100+39) =139 Mt 10 GC Vib ra t i 70 + (0.30 Mt ng Scr een - + 30 + (0.3x39) = 41.7x39) = 97.

70) = 99.70) =141.51 Mt Re-circulate to GC! .7x41.70) = 42.4 Pass: t = 4 hour th th New feed: 70% Undersize 30% Oversize 100% Efficiency (100+41.3x41.19 Mt ng Scr een - + 30 + (0.70 Mt 10 GC Vib ra t i 70 + (0.

7x42.76 Mt ng Scr een - + 30 + (0.5 Pass: t = 5 hour th th New feed: 70% Undersize 30% Oversize 100% Efficiency (100+42.51) = 42.51) = 99.51) =142.51 Mt 10 GC Vib ra t i 70 + (0.3x42.75 Mt Re-circulate to GC! .

75) =142.75 Mt 10 GC Vib ra t i 70 + (0.75) = 42.93 Mt ng Scr een - + 30 + (0.7x42.6 Pass: t = 6 hour th th New feed: 70% Undersize 30% Oversize 100% Efficiency (100+42.83 Mt Re-circulate to GC! .3x42.75) = 99.

98 Mt ng Scr een - + 30 + (0.83) = 99.7 Pass: t = 7 hour th th New feed: 70% Undersize 30% Oversize 100% Efficiency (100+42.7x42.83) = 42.83) =142.85 Mt Re-circulate to GC! .3x42.83 Mt 10 GC Vib ra t i 70 + (0.

7x42.8 Pass: t = 8 hour th th New feed: 70% Undersize 30% Oversize 100% Efficiency (100+42.85) = 42.3x42.85 Mt Re-circulate to GC! .99 Mt ng Scr een - + 30 + (0.85) = 99.85) =142.85 Mt 10 GC Vib ra t i 70 + (0.

7x42.86 Mt Re-circulate to GC! .85 Mt 10 GC Vib ra t i 70 + (0.85) = 42.85) =142.99 Mt ng Scr een - + 30 + (0.85) = 99.3x42.9 Pass: t = 9 hour th th New feed: 70% Undersize 30% Oversize 100% Efficiency (100+42.

7x42.85) = 42.10 Pass: t = 10 hour th th New feed: 70% Undersize 30% Oversize 100% Efficiency (100+42.86 Mt Re-circulate to GC! .99 Mt ng Scr een - + 30 + (0.85) =142.85 Mt 10 GC Vib ra t i 70 + (0.3x42.85) = 99.

Total Feed • Total feed is now computed as: Total Feed  Fresh Feed  Circulating Load  100 Mt  42.86 Mt  142.86 Mt .

R i  Where: F Ri = Initial Feed = %Oversize of Crusher Product .Total Feed • May also be computed using the formula: F Total Feed  1 .

86 Mt .Total Feed • Using the formula.7  142.R i  100 Mt 100 Mt   1  0. total feed may be computed as: F Total Feed  1 .3 0.

½” – 30% + ½” – Single-deck Vibrating Screen • ½” aperture • Screen Efficiency: 90% .Problem #2 • Given: – 100 Mt/h ROM feed – Primary Gyratory Crusher • Product particle size analysis: – 70% .

there are particles. supposedly undersize. that report to the oversize fraction! • Formula: – Where: OSt %Eff  OSa %Eff = %Screen Efficiency OSt = True GC OS fraction OSa = Actual Screen OS fraction .Take Note: • Screen Efficiency → affected by blinding – at lower efficiencies.

we use: OSt %Eff  OSt  x • For the given problem.90  30 Mt  x 30Mt x  30Mt 0.Take Note: • To determine the amount of US that reported to OS.33Mt  3. we get: 30 Mt 0.33% of Feed .9  3.

Now.67 Mt ting S cr een - + (30+3.33) = 66.33) = 33. consider: 70% Undersize 30% Oversize 90% Efficiency • 1st Pass → 1st hour 100 Mt 10 GC Vib ra (70–3.33 Mt Re-circulate to GC! .

89 Mt ng Scr een - Re-circulate to GC! + 30+(33.7) – (133.33x0.44 Mt .33x0.2 Pass: t = 2 hour nd nd New feed: 70% Undersize 30% Oversize 90% Efficiency (100+33.033) = 44.3)+(133.033) = 88.33) =133.33x0.33x0.33 Mt 10 GC Vib ra t i 70+(33.

44x0.44x0.033) = 96.44x0.44x0.44) =144.7) – (144.3)+(144.30 Mt ng Scr een - Re-circulate to GC! + 30+(44.15 Mt .3 Pass: t = 3 hour rd rd New feed: 70% Undersize 30% Oversize 90% Efficiency (100+44.44 Mt 10 GC Vib ra t i 70+(44.033) = 48.

033) = 98.38 Mt .15x0.15x0.033) = 49.15x0.4 Pass: t = 4 hour th th New feed: 70% Undersize 30% Oversize 90% Efficiency (100+48.3)+(148.7) – (148.15x0.15) =148.15 Mt 10 GC Vib ra t i 70+(48.77 Mt ng Scr een - Re-circulate to GC! + 30+(48.

79 Mt .38x0.59 Mt ng Scr een - Re-circulate to GC! + 30+(49.38) =149.7) – (149.38x0.033) = 99.38 Mt 10 GC Vib ra t i 70+(49.38x0.033) = 49.5 Pass: t = 5 hour th th New feed: 70% Undersize 30% Oversize 90% Efficiency (100+49.3)+(149.38x0.

79x0.79x0.033) = 49.7) – (149.86 Mt ng Scr een - Re-circulate to GC! + 30+(49.79 Mt 10 GC Vib ra t i 70+(49.79x0.79) =149.6 Pass: t = 6 hour th th New feed: 70% Undersize 30% Oversize 90% Efficiency (100+49.93 Mt .3)+(149.033) = 99.79x0.

93x0.95 Mt ng Scr een - Re-circulate to GC! + 30+(49.98 Mt .93x0.93 Mt 10 GC Vib ra t i 70+(49.7) – (149.3)+(149.033) = 49.7 Pass: t = 7 hour th th New feed: 70% Undersize 30% Oversize 90% Efficiency (100+49.93x0.033) = 99.93) =149.93x0.

8 Pass: t = 8 hour th th New feed: 70% Undersize 30% Oversize 90% Efficiency (100+49.98 Mt ng Scr een - Re-circulate to GC! + 30+(49.7) – (149.98) =149.3)+(149.98x0.99 Mt .033) = 99.98x0.98x0.98x0.033) = 49.98 Mt 10 GC Vib ra t i 70+(49.

99x0.7) – (149.99 Mt ng Scr een - Re-circulate to GC! + 30+(49.99x0.99x0.033) = 99.9 Pass: t = 9 hour th th New feed: 70% Undersize 30% Oversize 90% Efficiency (100+49.3)+(149.99x0.00 Mt .033) = 50.99) =149.99 Mt 10 GC Vib ra t i 70+(49.

00x0.7) – (150.033) = 100.00x0.10 Pass: t = 10 hour th th New feed: 70% Undersize 30% Oversize 90% Efficiency (100+50.3)+(150.00) =150.00 Mt ng Scr een - Re-circulate to GC! + 30+(50.033) = 50.00 Mt 10 GC Vib ra t i 70+(50.00x0.00x0.00 Mt .

Wait now! Going back… 70% Undersize 30% Oversize 90% Efficiency • 1st Pass → 1st hour 100 Mt 10 GC Vib ra (70–3.33 Mt Re-circulate to GC! .33) = 33.33) = 66.67 Mt ting S cr een - + (30+3.

67%] 66.Observations: • Based on the 1st Pass.67% instead of the original [30% : 70%] 70% – We may “perceive” the screen efficiency to be 100% again! . we determine: – 33.67% of the Feed reports to Undersize • Thus. we can see that: – We use the OS/US cut-off of [33.33% of the Feed reports to Oversize – 66.33% : 66.

67% Undersize 33.33) = 66.67% Vib ra t i (70–3.1 Pass: t = 1 hour st st 66.33 Mt Re-circulate to GC! .33) = 33.33% 10 GC 66.33% Oversize 100% Efficiency 100 Mt 33.67 Mt ng Scr een - + (30+3.

67= 88.89 Mt ng Scr een - + 133.33 Mt 33.33 = 44.67% Undersize 33.33% 10 GC 66.33x0.33% Oversize 100% Efficiency (100+33.67% Vib ra t i 133.33x0.33) =133.44 Mt Re-circulate to GC! .2 Pass: t = 2 hour nd nd New feed: 66.

67= 96.33 = 48.44x0.44 Mt 10 GC Vib ra t i 144.67% Undersize 33.15 Mt Re-circulate to GC! .44) =144.33% Oversize 100% Efficiency (100+44.3 Pass: t = 3 hour rd rd New feed: 66.44x0.30 Mt ng Scr een - + 144.

67= 98.15x0.38 Mt Re-circulate to GC! .67% Undersize 33.15x0.15 Mt 10 GC Vib ra t i 148.77 Mt ng Scr een - + 148.15) =148.4 Pass: t = 4 hour th th New feed: 66.33 = 49.33% Oversize 100% Efficiency (100+48.

38 Mt 10 GC Vib ra t i 149.59 Mt ng Scr een - + 149.38) =149.33 = 49.38x0.38x0.67% Undersize 33.79 Mt Re-circulate to GC! .5 Pass: t = 5 hour th th New feed: 66.33% Oversize 100% Efficiency (100+49.67= 99.

6 Pass: t = 6 hour th th New feed: 66.79) =149.86 Mt ng Scr een - + 149.79x0.67= 99.79x0.67% Undersize 33.33% Oversize 100% Efficiency (100+49.79 Mt 10 GC Vib ra t i 149.93 Mt Re-circulate to GC! .33 = 49.

95 Mt ng Scr een - + 149.93x0.67= 99.67% Undersize 33.98 Mt Re-circulate to GC! .33 = 49.93 Mt 10 GC Vib ra t i 149.33% Oversize 100% Efficiency (100+49.93) =149.7 Pass: t = 7 hour th th New feed: 66.93x0.

98x0.67= 99.33% Oversize 100% Efficiency (100+49.67% Undersize 33.8 Pass: t = 8 hour th th New feed: 66.98 Mt ng Scr een - + 149.98 Mt 10 GC Vib ra t i 149.99 Mt Re-circulate to GC! .98x0.33 = 49.98) =149.

33% Oversize 100% Efficiency (100+49.99 Mt ng Scr een - + 149.33 = 50.99x0.00 Mt Re-circulate to GC! .33x0.99) =149.67% Undersize 33.67= 99.99 Mt 10 GC Vib ra t i 133.9 Pass: t = 9 hour th th New feed: 66.

00 Mt ng Scr een - + 150.10 Pass: t = 10 hour th th New feed: 66.67= 100.33% Oversize 100% Efficiency (100+50.00) =150.33 = 50.00x0.00x0.00 Mt Re-circulate to GC! .67% Undersize 33.00 Mt 10 GC Vib ra t i 150.

Total Feed • Total feed is now computed as: Total Feed  Fresh Feed  Circulating Load  100 Mt  50 Mt  150 Mt .

Total Feed • May also be computed using the formula: Total Feed     Where: F Ri %Eff Rj F Ri 1% Eff F  1 .R j     = Initial Feed = %Oversize of Crusher Product = % Screen Efficiency = Ri / %Eff .

R j   1 . total feed may be computed as: F F Total Feed   1 .67   1  0 .Total Feed • Using the formula.9    150 Mt .R i  %Eff   100 Mt 100 Mt   0 .3  0.