About the BallBal_Reverse Spreadsheet ...

Scope :
The Ballbal_Reverse spreadsheet was designed to compute the Size-by-Size Mass Balance around the Hydrocyclone
Classifiers of any given Conventional Ball Mill circuit, operating under the Reverse configuration (see Flowsheet), on
the basis of actual plant measurements.

Theoretical Framework :
Whenever actual grinding data are collected in a plant environment, they will invariably be affected by natural
experimental and measurement errors, in such a way that the basic mass balance equation around the circuit, for particles
of size di :
fiF F + fiMD MD = fiU U + fiO O

???

, for i = 1,n

will never be satisfied. In the above expression F, MD, U and O represent the mass flowrate of solids in the circuit fresh
feed, mill discharge, underflow and overflow streams, respectively. Similarly, fiF, fiMD, fiU and fiO represent the fraction of
those total respective streams corresponding to particles of size d i.
The Ballbal_Reverse routine allows for the calculation of a whole new set of corresponding adjusted or fitted values fiF,
fiMD, fiU and fiO, such that the objective functions :
fi = [ wF (fiF - fiF)2 + wMD (fiMD - fiMD)2 + wU (fiU - fiU)2 + wO(fiO - fiO)2 ]

,for every particle size di

are minimized and the adjusted values so generated strictly satisfy the mass balance restrictions :
fiF F + fiMD MD = fiU U + fiO O

, for i = 1,n

where wF, wMD, wU and wO are user defined weighting factors included to represent the relative quality and reliability of the
samples from each of the 4 streams and the mass flowrates F, MD, U and O are calculated as :
F =
MD =
U =
O =

F
F (CL)
F (CL)
F

and the Circulating Load (CL) is estimated from :

CL = { usd

[(fiO - fiF) / (fiMD - fiU)] + ufs (1/fSO - 1/fSF) / (1/fSMD -1/fSU) } / (usd + ufs)

all i

where fsF, fsMD, fsU and fsO are the weight fractions of total solids in the fresh feed, mill discharge, underflow and overflow
streams, respectively, and also usd and ufs are user defined weighting factors included to represent the relative quality and
reliability of the size distribution measurements vs. the percent solids measurements in all 4 streams. In general, a high
relative value of a weighting factor is indicative of a more reliable measurement with respect to the other measurements
participating in the same equations.

Moly-Cop Tools / 131104195.xls.ms_office

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A statistically sound weighting factor may be calculated as 100/(% error) 2; where (% error) corresponds to the combined
sampling and measuring error percentage.
The least-square minimization problem stated above may be linearized and solved through the Lagrange Multipliers
Method (see About ... in Cyclobal_Single).
Further refinement of the adjusted values so computed is achieved by imposing the condition that these values must
conform to the Plitt's Classification Efficiency curve : (see About ... in Cyclosim_Single)
Ei = Bpf + (1 - Bpf ) (1 - exp [ - 0.693 (di/d50c)m ])
with the aid of the Excel Subroutine Solver to minimize a least-square objective function with respect to parameters Bpf,
d50c and m.
Finally, the size distribution of the cyclone feed stream may be calculated on the basis of the adjusted values so obtained
for the fresh feed and mill discharge streams.
Data Input and Program Execution :
Most of the data required by the model must be defined in each corresponding unprotected white background cell inside the red double-lined border - of the here attached Data_File worksheet. Gray background cells contain the results
of the corresponding formulas there defined and are protected to avoid any accidental editing.
The remaining information required to run the program is entered in the Control_Panel worksheet, where the user is
requested to provide initial guesses of the Bpf, d50c and m parameters (see About ... in Cyclosim_Single). The Bpc
parameter is rarely used and was incorporated to take into account the possible short-circuit of coarse particles to the
overflow (as could be the case in highly pressurised cyclones). Finally, the user must specify the relative weighting factors
for the various feed, underflow and overflow streams plus the relative weighting factors for the size distribution and
percent solids measurements.
To run the program, select the objective function Cell E22 in Control_Panel and then, from the Tools Menu, select
Solver ..., then Min and then By Changing any combination of Cells C20:F20. Clicking on the Solve button will execute
the desired calculations.
Important Notice : Solver ... must be run every time any element of input data gets to be modified. Otherwise, the
current outputs are not valid.
Calculation results are summarized in the Reports worksheet.
An interesting feature of this routine is that the user has the option to save for later reference every analyzed data set by
copying the Data_File worksheet into as many as required Sample 1, Sample 2, etc. worksheets. For reprocessing these
data, simply copy the information back to the Data_File and re-run the Solver routine.
New Moly-Cop Tools users are invited to explore the brief comments inserted in each relevant cell, rendering the whole
utilization of the worksheets self-explanatory. Eventually, the user may wish to remove the view of the comments by
selecting Tools / Options / View / Comments / None.

Moly-Cop Tools / 131104195.xls.ms_office

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hat the basic mass balance equation around the circuit, for particles

included to represent the relative quality and reliability of the

included to represent the relative quality and

Moly-Cop Tools / 131104195.xls.ms_office

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contain the results

Moly-Cop Tools / 131104195.xls.ms_office

Page 4

2/25/2013 / 1:44 PM

TM

Moly-Cop Tools

Ballbal_Reverse : MASS BALANCE CLOSURE AROUND A BALL MILL GRINDING CIRCUIT

Sample N

Weighting Factors
Streams :
Fresh Feed
Mill Discharge
Cyclone Feed
Cyclone U'flow
Cyclone O'flow

0
1
1
1
1

Size Distr.
% Solids

1
1

Initial Guesses :
Bpf
Bpc
0.480
0.001
Obj. Function :

d50c
108.8

% Passing

100

10

m
1.391

Mill Discharge
Cyclone U'flow

0.010

Cyclone O'flow
Fresh Feed

Classifier Constants :
a1
a2
a3
a4
l

2.31
0.921
38.46
0.667
0.881

Moly-Cop Tools / 131104195.xls.ms_office

1
10

100

1000

10000

Particle Size, microns

Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.

2/25/2013 / 1:44 PM

Moly-Cop Tools

TM

BALLBAL : Mass Balance Closure around a Ball Mill Grinding Circuit

Circuit Type

REVERSE

Remarks

Sample N

Antamina
Muestreo Molino 1 - Menor Tonelaje

Mill Dimensions and Operating Conditions

Diameter
Length
Speed
Charge
ft
ft
% Critical
Filling,%
24.0
36.0
70.0
36.00
rpm
10.95

Balls
Filling,%
36.00

Cyclone Dimensions (inches) and Operating Pressure (psi)

Number
Diameter
Height
Inlet
Vortex
13
26.0
75.0
10.00
8.00

Interstitial
Slurry Filling,%
100.00

Apex
5.00

Lift
Angle, ()
26.9

7891
0
1471
9362
10.0
10402

Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW

Charge
Volume,
m3
166.35

psi
4.50

Mill Charge Weight, tons

Ball
Slurry
Charge
Interstitial
Excess
773.52
144.23
0.00

Feedrate, ton/hr (dry)

1183.3

Ore Density, ton/m3

Balls Density, ton/m3

3.40
7.75

Apparent
Density
ton/m3
5.517

EXPERIMENTAL SIZE DISTRIBUTIONS

i

Mesh
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

1.05
3/4"
1/2"
3/8"
1/4"
4
6
10
14
20
28
35
48
65
100
150
200
270
325
400
-400

Opening

Mid-Size

25400
19050
12700
9500
6700
4750
3350
1700
1180
850
600
425
300
212
150
106
75
53
45
38
0

Totals
% Solids
Slurry Density, ton/m3
Weighting Factor

Moly-Cop Tools / 131104195.xls.ms_office

21997
15554
10984
7978
5641
3989
2386
1416
1001
714
505
357
252
178
126
89
63
49
41
19

ton/hr

0.00
10.65
31.95
40.23
37.87
53.25
121.88
84.72
69.10
81.65
84.37
74.19
67.45
66.26
56.80
61.53
60.35
16.57
15.38
149.10
1183.30

Fresh Feed
% Retained % Passing

0.00
0.90
2.70
3.40
3.20
4.50
10.30
7.16
5.84
6.90
7.13
6.27
5.70
5.60
4.80
5.20
5.10
1.40
1.30
12.60
100.00

100.00
100.00
99.10
96.40
93.00
89.80
85.30
75.00
67.84
62.00
55.10
47.97
41.70
36.00
30.40
25.60
20.40
15.30
13.90
12.60
0.00

73.82
2.088
0.000

ton/hr

Mill Discharge
% Retained % Passing

0.00
0.00
37.63
13.39
38.27
57.40
159.44
190.69
166.45
350.76
776.78
670.91
1039.53
860.96
586.73
344.39
286.99
114.80
38.27
644.13
6377.51

0.00
0.00
0.59
0.21
0.60
0.90
2.50
2.99
2.61
5.50
12.18
10.52
16.30
13.50
9.20
5.40
4.50
1.80
0.60
10.10
100.00

100.00
100.00
100.00
99.41
99.20
98.60
97.70
95.20
92.21
89.60
84.10
71.92
61.40
45.10
31.60
22.40
17.00
12.50
10.70
10.10
0.00

76.31
2.168
1.000

ton/hr

0.00
10.65
69.58
53.62
76.13
110.65
281.32
275.41
235.56
432.41
861.15
745.11
1106.98
927.23
643.53
405.92
347.34
131.36
53.65
793.22
7560.81

Cyclone Feed
% Retained % Passing

0.00
0.14
0.92
0.71
1.01
1.46
3.72
3.64
3.12
5.72
11.39
9.85
14.64
12.26
8.51
5.37
4.59
1.74
0.71
10.49
100.00

100.00
100.00
99.86
98.94
98.23
97.22
95.76
92.04
88.40
85.28
79.56
68.17
58.32
43.68
31.41
22.90
17.53
12.94
11.20
10.49
0.00

65.00
1.848
1.000

ton/hr

Cyclone U'flow
% Retained % Passing

0.00
0.00
26.79
75.25
70.15
102.04
299.74
267.86
229.59
414.54
794.64
672.19
1001.27
886.47
554.84
261.48
191.33
76.53
19.13
433.67
6377.51

0.00
0.00
0.42
1.18
1.10
1.60
4.70
4.20
3.60
6.50
12.46
10.54
15.70
13.90
8.70
4.10
3.00
1.20
0.30
6.80
100.00

100.00
100.00
100.00
99.58
98.40
97.30
95.70
91.00
86.80
83.20
76.70
64.24
53.70
38.00
24.10
15.40
11.30
8.30
7.10
6.80
0.00

77.81
2.219
1.000

ton/hr

Cyclone O'flow
% Retained % Passing

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
115.96
111.23
155.01
124.25
149.10
62.71
18.93
446.10
1183.30

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
9.80
9.40
13.10
10.50
12.60
5.30
1.60
37.70
100.00

100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
90.20
80.80
67.70
57.20
44.60
39.30
37.70
0.00

38.39
1.372
1.000

2/25/2013 / 1:44 PM

Moly-Cop Tools

TM

Remarks

Sample N

Antamina
Muestreo Molino 1 - Menor Tonelaje
38.33 % Solids
44.61 % - Size 18
145.4 P80

4.50 psi

Bpf
Bpw

ton/hr
F80

Water,
m3/hr

0.480
0.545

1183.3
2389

13 # of Cyclones
8.00 Vortex
5.00 Apex
75.43 % Solids

3
-107.3 Water, m /hr

1591.6
Gross kW
% Balls
% Critical
% Solids

kWh/ton
Wio

10402.0
36.00
70.00
76.31

Circ. Load
m3/hr
% Solids

590.88
6586
66.16

8.79
14.07

Moly-Cop Tools / 131104195.xls.ms_office / Flowsheet

2/25/2013 / 1:44 PM

Moly-Cop Tools

TM

Sample N

Cyclone
U'flow
6991.9
2277.9
9269.7
4334.3
2.139
47.4
75.4

Cyclone
O'flow
1183.3
1904.0
3087.3
2252.0
1.371
15.5
38.3

BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks : Antamina
Muestreo Molino 1 - Menor Tonelaje

CIRCUIT MASS BALANCE

Configuration : REVERSE

Ore, ton/hr
Water, m3/hr
Slurry, ton/hr
Slurry, m3/hr
Slurry Dens., ton/m3
% Solids (by volume)
% Solids (by weight)

Fresh
Feed
1183.3
419.7
1603.0
767.7
2.088
45.3
73.8

Mill
Mill
Feed
Discharge
6991.9
6991.9
2277.9
2170.6
9269.7
9162.4
4334.3
4227.0
2.139
2.168
47.4
48.6
75.4
76.3

Sump
Water
0.0
1591.6
1591.6
1591.6
1.000
0.0
0.0

Cyclone
Feed
8175.2
4181.9
12357.0
6586.3
1.876
36.5
66.2

Particle Size Distributions (Cummulative % Passing)

i

Mesh

Opening

1.05

3/4"
1/2"
4 3/8"
5 1/4"
2
3

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

4
6
10
14
20
28
35
48
65
100
150
200
270
325
400

25400
19050
12700
9500
6700
4750
3350
1700
1180
850
600
425
300
212
150
106
75
53
45
38

D80, microns

100.00
100.00
99.10
96.40
93.00
89.80
85.30
75.00
67.84
62.00
55.10
47.97
41.70
36.00
30.40
25.60
20.40
15.30
13.90
12.60

100.00
100.00
99.93
99.24
98.21
97.09
95.46
90.95
86.76
83.17
76.65
63.96
53.24
37.01
24.01
15.81
11.59
8.28
7.05
6.66

100.00
100.00
100.08
99.84
99.40
98.82
97.94
95.17
92.19
89.59
84.23
72.71
62.90
46.65
32.64
22.90
17.69
13.24
11.38
10.91

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

100.00
100.00
99.94
99.35
98.47
97.51
96.11
92.25
88.67
85.60
80.01
69.13
59.83
45.11
32.31
23.30
18.08
13.54
11.74
11.15

100.00
100.00
99.93
99.24
98.21
97.09
95.46
90.95
86.76
83.17
76.65
63.96
53.24
37.01
24.01
15.81
11.59
8.28
7.05
6.66

100.00
100.00
100.00
100.00
99.99
99.99
99.98
99.95
99.93
99.92
99.88
99.71
98.76
93.00
81.36
67.49
56.41
44.61
39.46
37.69

2389

720

532

600

720

145.4

Specific Energy Consumption :

Operational Work Index :

Moly-Cop Tools / 131104195.xls.ms_office

8.79 KWH/ton (Gross)

14.07 KWH/ton

Page 8

2/25/2013 / 1:44 PM

Moly-Cop Tools

TM

Sample N

BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks : Antamina
Muestreo Molino 1 - Menor Tonelaje

CLASSIFIERS PERFORMANCE
Number of Cyclones :
Cyclone Dimensions, in :
Diameter
Height
Inlet
Vortex
Apex
Ore Density, ton/m3

13

Operating Conditions :
Feed Flowrate, m3/hr
Pressure, psi
D50 (corr.), microns
Water By-Pass, %
Solids By-Pass, %
Plitt's Parameter
Circulating Load, %

26.00
75.00
10.00
8.00
5.00
3.40

6586.3
4.5
108.8
54.5
48.0
1.39
591

Mass Balance around the Classifiers

Mesh
1.05

3/4"
1/2"
4 3/8"
5 1/4"
2
3

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

4
6
10
14
20
28
35
48
65
100
150
200
270
325
400

Opening
25400
19050
12700
9500
6700
4750
3350
1700
1180
850
600
425
300
212
150
106
75
53
45
38

Ore, ton/hr
Water, m3/hr
Slurry, ton/hr
Slurry, m3/hr
Slurry Dens., ton/m3
% Solids (by volume)
% Solids (by weight)

Moly-Cop Tools / 131104195.xls.ms_office

Mid-Size
21997
15554
10984
7978
5641
3989
2386
1416
1001
714
505
357
252
178
126
89
63
49
41
19

Size Distributions, % Passing

Feed
U'flow
O'flow
100.00
100.00
99.94
99.35
98.47
97.51
96.11
92.25
88.67
85.60
80.01
69.13
59.83
45.11
32.31
23.30
18.08
13.54
11.74
11.15

100.00
100.00
99.93
99.24
98.21
97.09
95.46
90.95
86.76
83.17
76.65
63.96
53.24
37.01
24.01
15.81
11.59
8.28
7.05
6.66

100.00
100.00
100.00
100.00
99.99
99.99
99.98
99.95
99.93
99.92
99.88
99.71
98.76
93.00
81.36
67.49
56.41
44.61
39.46
37.69

8175.2
4181.9
12357.0
6586.3
1.876
36.5
66.2

6991.9
2277.9
9269.7
4334.3
2.139
47.4
75.4

1183.3
1904.0
3087.3
2252.0
1.371
15.5
38.3

Page 9

Classifier Efficiency
Actual
Corrected
0.999
0.999
0.999
0.999
0.999
0.999
0.999
0.999
0.999
0.999
0.998
0.985
0.943
0.868
0.777
0.692
0.624
0.586
0.566
0.511

1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.997
0.973
0.893
0.748
0.573
0.409
0.277
0.204
0.165
0.059

Classifier Constants
a1
a2
a3
a4
l

2.313
0.921
38.460
0.667
0.881

2/25/2013 / 1:44 PM

Moly-Cop Tools

TM

Sample N

BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks : Antamina
Muestreo Molino 1 - Menor Tonelaje

BALL MILL PERFORMANCE

Diameter, ft
Length, ft
Speed, % Critical
App. Density, ton/m3
Charge Level, %
Balls Filling, %
Lift Angle, ()

Mesh

1.05

3/4"
3 1/2"
4 3/8"
5 1/4"
2

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

4
6
10
14
20
28
35
48
65
100
150
200
270
325
400

Opening
25400
19050
12700
9500
6700
4750
3350
1700
1180
850
600
425
300
212
150
106
75
53
45
38

Mill Power, KW (Gross)

Mill Power, KW (Net)
Throughput, ton/hr
% Solids (by weight)
Sp. Energy, KWH/ton
Reduction Ratio

24.0
36.0
70.0
5.52
36.0
36.0
26.9
Size Distributions
Mill
Mill
Feed
Discharge

Mid-Size
21997
15554
10984
7978
5641
3989
2386
1416
1001
714
505
357
252
178
126
89
63
49
41
19

D80, microns

Moly-Cop Tools / 131104195.xls.ms_office

10402
9362
6991.9
75.4
1.49
1.35

Page 10

100.00
100.00
99.93
99.24
98.21
97.09
95.46
90.95
86.76
83.17
76.65
63.96
53.24
37.01
24.01
15.81
11.59
8.28
7.05
6.66

100.00
100.00
100.08
99.84
99.40
98.82
97.94
95.17
92.19
89.59
84.23
72.71
62.90
46.65
32.64
22.90
17.69
13.24
11.38
10.91

720

532

2/25/2013 / 1:44 PM

Number of Cyclones
Classifier Dimensions, inches.
DC
h
DI
DO
26
75
10
8
Classifier Constants
a1
a2
a3
a4
2.3126884 0.920778 38.46016 0.666879
Circulating Load, CL
Slurry Split, S
Cyclone Pressure, ft
Cyclone Pressure, lb/in2
Corrected Cut Size, d50c, microns
Water By-Pass
Fines By-Pass
Coarse By-Pass
Plitt's Parameter
Opening

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

25400
19050
12700
9500
6700
4750
3350
1700
1180
850
600
425
300
212
150
106
75

Mid-Size

21997.05
15554.26
10984.08
7978.095
5641.365
3989.048
2386.42
1416.333
1001.499
714.1428
504.9752
357.0714
252.1904
178.3255
126.0952
89.16277

13
DU
5
l
0.881127
5.908775
1.924616
5.539287
4.50
108.7665
0.544701
0.479951
0.000849
1.39058

Solids, tons
Water, m3/hr
Slurry, tons
Slurry, m3/hr
Solids Density, ton/m3
Slurry Density, ton/m3
% Solids (by volume)
% Solids (by weight)

Cyclone
Feed
581.60
297.51
879.1088
468.5672
3.4
1.876164
36.50683
66.16

Cyclone
U'flow
497.42
162.05
659.4707
308.3523
3.4
2.138692
47.44552
75.43

Cyclone
O'flow
84.18288
135.46
219.6381
160.2149
3.4
1.370897
15.45404
38.33

ton/hr (model)
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow

Classifier
Efficiency

0.999151
0.999151
0.999151
0.999151
0.999151
0.999151
0.999151
0.999151
0.99915
0.999111
0.997671
0.985236
0.943412
0.868297
0.777495
0.69222

0.00
4.52
44.93
66.08
72.69
105.69
291.93
271.06
232.12
422.12
822.84
703.10
1112.89
967.83
681.74
394.29

Page 11

0
4.511169
44.88881
66.02845
72.62528
105.5989
291.6834
270.8287
231.923
421.7401
820.9194
692.7227
1049.91
840.3601
530.0463
272.9319

0.00
0.00
0.04
0.06
0.06
0.09
0.25
0.23
0.20
0.38
1.92
10.38
62.98
127.47
151.69
121.35

% Retained (model)
Cyclone
Cyclone
Feed
U'flow

0.00
0.06
0.59
0.87
0.96
1.40
3.86
3.59
3.07
5.58
10.88
9.30
14.72
12.80
9.02
5.21

0.00
0.07
0.69
1.02
1.12
1.63
4.51
4.19
3.59
6.52
12.70
10.71
16.24
13.00
8.20
4.22

18
19
20
21

53 63.0476
45 48.83646
38 41.35215
0
19

0.623881
0.585634
0.565734
0.510792
Total

Page 12

343.35
135.90
44.67
843.08

214.2112
79.58928
25.27229
430.6393

129.14
56.31
19.40
412.44

4.54
1.80
0.59
11.15

3.31
1.23
0.39
6.66

7560.81

6466.43

1094.38

100.00

100.00

(model)
Cyclone
O'flow

0.00
0.00
0.00
0.01
0.01
0.01
0.02
0.02
0.02
0.03
0.18
0.95
5.75
11.65
13.86
11.09

% Passing (model)
Cyclone
Cyclone
Cyclone
Feed
U'flow
O'flow
100.00
100.00
99.94
99.35
98.47
97.51
96.11
92.25
88.67
85.60
80.01
69.13
59.83
45.11
32.31
23.30
18.08

100.00
100.00
99.93
99.24
98.21
97.09
95.46
90.95
86.76
83.17
76.65
63.96
53.24
37.01
24.01
15.81
11.59

100.00
100.00
100.00
100.00
99.99
99.99
99.98
99.95
99.93
99.92
99.88
99.71
98.76
93.00
81.36
67.49
56.41

% Passing (exp)
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow
100.00
100.00
99.94
99.35
98.47
97.51
96.11
92.25
88.67
85.60
80.01
69.13
59.83
45.11
32.31
23.30
18.08

100.00
100.00
100.00
99.58
98.40
97.30
95.70
91.00
86.80
83.20
76.70
64.24
53.70
38.00
24.10
15.40
11.30

100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
90.20
80.80
67.70
57.20

Page 13

(Weighted Error)^2
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow
1
1
1
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.000
0.001
0.001

0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.000
0.000
0.000

% Retaine
Cyclone
Feed

11.80
5.15
1.77
37.69

13.54
11.74
11.15

8.28
7.05
6.66

44.61
39.46
37.69

13.54
11.74
11.15

8.30
7.10
6.80

44.60
39.30
37.70

100.00

Page 14

0.000
0.000
0.000

0.000
0.000
0.000

0.000
0.000
0.000

0.000

0.000

Overall
0.000

% Retained
Cyclone Cyclone
U'flow
O'flow

Cyclone
Feed

% Passing
Cyclone Cyclone
U'flow
O'flow

Page 15

Sample 1

Moly-Cop Tools

TM

BALLBAL : Mass Balance Clos

Circuit Type

REVERSE

Remarks

Base Case Example

Mill Dimensions and Operating Conditions

Diameter
Length
Speed
Charge
ft
ft
% Critical
Filling,%
18.5
22.0
72.0
38.00
rpm
12.82

Balls
Filling,%
38.00

Cyclone Dimensions (inches) and Operating Pressure (psi)

Number
Diameter
Height
Inlet
Vortex
10
20.0
75.0
3.50
7.50

Mesh
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
-400

Opening
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0

Mid-Size

21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19

Totals
% Solids
Slurry Density, ton/m3
Weighting Factor

ton/hr

0.00
20.00
66.40
56.28
41.32
33.36
27.36
21.64
20.40
15.60
14.16
12.04
10.36
8.84
7.52
6.48
5.52
4.72
3.40
24.60
400.00

Interstitial
Slurry Filling,%
100.00

Apex
4.05

Fresh Feed
% Retained % Passing

0.00
5.00
16.60
14.07
10.33
8.34
6.84
5.41
5.10
3.90
3.54
3.01
2.59
2.21
1.88
1.62
1.38
1.18
0.85
6.15
100.00

100.00
100.00
95.00
78.40
64.33
54.00
45.66
38.82
33.41
28.31
24.41
20.87
17.86
15.27
13.06
11.18
9.56
8.18
7.00
6.15
0.00

95.00
2.569
0.000

Page 16

psi
9.41

Mill Discharge
ton/hr

0.00
17.19
39.23
38.54
35.00
36.46
41.78
48.49
63.45
74.69
95.00
114.06
128.50
128.56
114.27
92.85
70.83
53.26
39.03
308.62
1539.79

Sample 1

L : Mass Balance Closure around a Ball Mill Grinding Circuit

Sample N

Lift
Angle, ()
35.0

3348
0
536
3885
10.0
4316

Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW

Charge
Volume,
m3
63.76

Mill Charge Weight, tons

Ball
Slurry
Charge
Interstitial
Excess
296.48
47.48
0.00

Feedrate, ton/hr (dry)

400.0

Ore Density, ton/m3

Balls Density, ton/m3

2.80
7.75

EXPERIMENTAL SIZE DISTRIBUTIONS

Mill Discharge
% Retained % Passing

0.00
1.12
2.55
2.50
2.27
2.37
2.71
3.15
4.12
4.85
6.17
7.41
8.35
8.35
7.42
6.03
4.60
3.46
2.53
20.04
100.00

100.00
100.00
98.88
96.34
93.83
91.56
89.19
86.48
83.33
79.21
74.36
68.19
60.78
52.44
44.09
36.67
30.64
26.04
22.58
20.04
0.00

72.00
1.862
1.000

ton/hr

Cyclone Feed
% Retained % Passing

0.00
37.19
105.63
94.82
76.32
69.82
69.14
70.13
83.85
90.29
109.16
126.10
138.86
137.40
121.79
99.33
76.35
57.98
42.43
333.22
1939.79

0.00
1.92
5.45
4.89
3.93
3.60
3.56
3.62
4.32
4.65
5.63
6.50
7.16
7.08
6.28
5.12
3.94
2.99
2.19
17.18
100.00

100.00
100.00
98.08
92.64
87.75
83.81
80.22
76.65
73.04
68.71
64.06
58.43
51.93
44.77
37.69
31.41
26.29
22.35
19.37
17.18
0.00

64.10
1.701
1.000

Page 17

ton/hr

Cyclone U'flow
% Retained % Passing

0.00
37.19
105.63
94.82
76.32
69.82
69.14
70.13
83.85
90.26
108.52
121.55
123.90
108.66
83.81
59.89
41.27
28.87
19.98
146.20
1539.79

0.00
2.42
6.86
6.16
4.96
4.53
4.49
4.55
5.45
5.86
7.05
7.89
8.05
7.06
5.44
3.89
2.68
1.88
1.30
9.49
100.00

100.00
100.00
97.58
90.72
84.57
79.61
75.08
70.59
66.03
60.59
54.72
47.68
39.78
31.74
24.68
19.24
15.35
12.67
10.79
9.49
0.00

76.00
1.955
1.000

Sample 1

Apparent
Density
ton/m3
5.395

ton/hr

Cyclone O'flow
% Retained % Passing

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.65
4.55
14.96
28.74
37.98
39.44
35.09
29.10
22.45
187.02
400.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.16
1.14
3.74
7.18
9.49
9.86
8.77
7.28
5.61
46.75
100.00

100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.83
98.69
94.95
87.77
78.27
68.41
59.64
52.37
46.75
0.00

Circ.
Load

3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849
3.849

Circ. Load
W. Factors

40.00
1.346
1.000

Page 18

3.849

3.849

CL (ave)

3.849

Lambda

0.00000
(0.00000)
(0.00000)
(0.00000)
(0.00000)
(0.00000)
(0.00000)
(0.00000)
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000

(0.00000)

Cyclone Feed (pre-a

ton/hr

0.00
37.19
105.63
94.82
76.32
69.82
69.14
70.13
83.85
90.29
109.16
126.10
138.86
137.40
121.79
99.33
76.35
57.98
42.43
333.22
1939.79

Sample 1

NO DATA INPUT REQUIRED IN THIS SECTOR

Cyclone Feed (pre-adjusted)

% Retained % Passing

0.00
1.92
5.45
4.89
3.93
3.60
3.56
3.62
4.32
4.65
5.63
6.50
7.16
7.08
6.28
5.12
3.94
2.99
2.19
17.18
100.00

adj.

100.00
100.00
98.08
92.64
87.75
83.81
80.22
76.65
73.04
68.71
64.06
58.43
51.93
44.77
37.69
31.41
26.29
22.35
19.37
17.18

0.00
0.00
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)
(0.00)

64.10

(0.00)

Cyclone O'flow (pre-adjusted)

ton/hr
% Retained % Passing

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.65
4.55
14.96
28.74
37.98
39.44
35.09
29.10
22.45
187.02
400.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.16
1.14
3.74
7.18
9.49
9.86
8.77
7.28
5.61
46.75
100.00

Page 19

adj.

100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.83
98.69
94.95
87.77
78.27
68.41
59.64
52.37
46.75

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

40.00

0.00

Cyclone U'flow (pre-adjusted)

ton/hr

0.00
37.19
105.63
94.82
76.32
69.82
69.14
70.13
83.85
90.26
108.52
121.55
123.90
108.66
83.81
59.89
41.27
28.87
19.98
146.20
1539.79

Sample 1

Cyclone U'flow (pre-adjusted)

% Retained % Passing

0.00
2.42
6.86
6.16
4.96
4.53
4.49
4.55
5.45
5.86
7.05
7.89
8.05
7.06
5.44
3.89
2.68
1.88
1.30
9.49
100.00

adj.

100.00
100.00
97.58
90.72
84.57
79.61
75.08
70.59
66.03
60.59
54.72
47.68
39.78
31.74
24.68
19.24
15.35
12.67
10.79
9.49

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

76.00

0.00

Page 20