Panunumpa NG Propesyonal

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%
1st Pass: t = 1st hour
70% Undersize
100 Mt 30% Oversize
100% Efficiency
10 GC 30%
30 Mt Re-circulate
+½“ to GC!
70% +
70 Mt
-
–½“
2nd Pass: t = 2nd hour
New feed: 70% Undersize
(100+30) 30% Oversize
=130 Mt 100% Efficiency
10 GC 30%
Re-circulate
30 + (0.3x30)
to GC!
70% + = 39 Mt
70 + (0.7x30)
-
= 91 Mt
3rd Pass: t = 3rd hour
(100+39) 30% Oversize
=139 Mt 100% Efficiency
10 GC
Re-circulate
30 + (0.3x39)
to GC!
+ = 41.70 Mt
70 + (0.7x39)
-
= 97.30 Mt
4th Pass: t = 4th hour
(100+41.70) 30% Oversize
=141.70 Mt 100% Efficiency
10 GC
Re-circulate
30 + (0.3x41.70) to GC!
+ = 42.51 Mt
70 + (0.7x41.70)
-
= 99.19 Mt
(100+42.51) 30% Oversize
10 GC
Re-circulate
30 + (0.3x42.51) to GC!
+ = 42.75 Mt
70 + (0.7x42.51)
-
= 99.76 Mt
(100+42.75) 30% Oversize
10 GC
Re-circulate
30 + (0.3x42.75) to GC!
+ = 42.83 Mt
70 + (0.7x42.75)
-
= 99.93 Mt
(100+42.83) 30% Oversize
10 GC
Re-circulate
30 + (0.3x42.83) to GC!
+ = 42.85 Mt
70 + (0.7x42.83)
-
= 99.98 Mt
(100+42.85) 30% Oversize
10 GC
Re-circulate
30 + (0.3x42.85) to GC!
+ = 42.85 Mt
70 + (0.7x42.85)
-
= 99.99 Mt
(100+42.85) 30% Oversize
10 GC
Re-circulate
30 + (0.3x42.85) to GC!
+ = 42.86 Mt
70 + (0.7x42.85)
-
= 99.99 Mt
(100+42.85) 30% Oversize
10 GC
Re-circulate
30 + (0.3x42.85) to GC!
+ = 42.86 Mt
70 + (0.7x42.85)
-
= 99.99 Mt
Total Feed
• Total feed is now computed as:
Total Feed  Fresh Feed  Circulatin g Load

 100Mt  42.86Mt
 142.86Mt
Total Feed
• May also be computed using the formula:
F
Total Feed 
1 - R i 
Where: F = Initial Feed
Ri = %Oversize of Crusher Product
Total Feed
• Using the formula, total feed may be
computed as:
F
Total Feed 
1 - R i 
100Mt 100Mt
 
1  0.3 0.7
 142.86Mt
Problem #2
• 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: 90%
Take Note:
• Screen Efficiency → affected by blinding
– at lower efficiencies, there are particles,
supposedly undersize, that report to the
oversize fraction!
• Formula: OSt
%Eff 
OSa
– Where: %Eff = %Screen Efficiency
OSt = True GC OS fraction
OSa = Actual Screen OS fraction
Take Note:
• To determine the OSt
amount of US that %Eff 
reported to OS, we use:
OSt  x
• For the given problem, 30Mt

0.90 
we get: 30Mt  x
30Mt
x  30Mt
0.9
 3.33Mt  3.33% of Feed
Now, consider:
70% Undersize
• 1st Pass → 1st hour 30% Oversize
90% Efficiency
100 Mt
10 GC
Re-circulate
to GC!
(30+3.33) =
+ 33.33 Mt
-
(70–3.33) =
66.67 Mt
New feed:
70% Undersize
(100+33.33)
30% Oversize
=133.33 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(33.33x0.3)+(133.33x0.033)
= 44.44 Mt
+
70+(33.33x0.7) – -
(133.33x0.033)
= 88.89 Mt
New feed:
70% Undersize
(100+44.44)
30% Oversize
=144.44 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(44.44x0.3)+(144.44x0.033)
= 48.15 Mt
+
70+(44.44x0.7) – -
(144.44x0.033)
= 96.30 Mt
New feed:
70% Undersize
(100+48.15)
30% Oversize
=148.15 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(48.15x0.3)+(148.15x0.033)
= 49.38 Mt
+
70+(48.15x0.7) – -
(148.15x0.033)
= 98.77 Mt
New feed:
70% Undersize
(100+49.38)
30% Oversize
=149.38 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(49.38x0.3)+(149.38x0.033)
= 49.79 Mt
+
70+(49.38x0.7) – -
(149.38x0.033)
= 99.59 Mt
New feed:
70% Undersize
(100+49.79)
30% Oversize
=149.79 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(49.79x0.3)+(149.79x0.033)
= 49.93 Mt
+
70+(49.79x0.7) – -
(149.79x0.033)
= 99.86 Mt
New feed:
70% Undersize
(100+49.93)
30% Oversize
=149.93 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(49.93x0.3)+(149.93x0.033)
= 49.98 Mt
+
70+(49.93x0.7) – -
(149.93x0.033)
= 99.95 Mt
New feed:
70% Undersize
(100+49.98)
30% Oversize
=149.98 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(49.98x0.3)+(149.98x0.033)
= 49.99 Mt
+
70+(49.98x0.7) – -
(149.98x0.033)
= 99.98 Mt
New feed:
70% Undersize
(100+49.99)
30% Oversize
=149.99 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(49.99x0.3)+(149.99x0.033)
= 50.00 Mt
+
70+(49.99x0.7) – -
(149.99x0.033)
= 99.99 Mt
New feed:
70% Undersize
(100+50.00)
30% Oversize
=150.00 Mt
90% Efficiency
10 GC Re-circulate
to GC!
30+(50.00x0.3)+(150.00x0.033)
= 50.00 Mt
+
70+(50.00x0.7) – -
(150.00x0.033)
= 100.00 Mt
Wait now! Going back…
70% Undersize
• 1st Pass → 1st hour 30% Oversize
90% Efficiency
100 Mt
10 GC
Re-circulate
to GC!
(30+3.33) =
+ 33.33 Mt
-
(70–3.33) =
66.67 Mt
Observations:
• Based on the 1st Pass, we determine:
– 33.33% of the Feed reports to Oversize
– 66.67% of the Feed reports to Undersize
• Thus, we can see that:

– We use the OS/US cut-off of [33.33% : 66.67%]
instead of the original [30% : 70%]
– We may “perceive” the screen efficiency to be
100% again!
1st Pass: t = 1st hour
66.67% Undersize
100 Mt 33.33% Oversize
100% Efficiency
10 GC 33.33%
(30+3.33) = Re-circulate
66.67% 33.33 Mt to GC!
+
-
(70–3.33) =
66.67 Mt
New feed: 66.67% Undersize
(100+33.33) 33.33% Oversize
10 GC 33.33%
Re-circulate
133.33x0.33 =
66.67% to GC!
+ 44.44 Mt
133.33x0.67=
-
88.89 Mt
(100+44.44) 33.33% Oversize
10 GC
Re-circulate
144.44x0.33 =
to GC!
+ 48.15 Mt
144.44x0.67=
-
96.30 Mt
(100+48.15) 33.33% Oversize
10 GC
Re-circulate
148.15x0.33 =
to GC!
+ 49.38 Mt
148.15x0.67=
-
98.77 Mt
(100+49.38) 33.33% Oversize
10 GC
Re-circulate
149.38x0.33 =
to GC!
+ 49.79 Mt
149.38x0.67=
-
99.59 Mt
(100+49.79) 33.33% Oversize
10 GC
Re-circulate
149.79x0.33 =
to GC!
+ 49.93 Mt
149.79x0.67=
-
99.86 Mt
(100+49.93) 33.33% Oversize
10 GC
Re-circulate
149.93x0.33 =
to GC!
+ 49.98 Mt
149.93x0.67=
-
99.95 Mt
(100+49.98) 33.33% Oversize
10 GC
Re-circulate
149.98x0.33 =
to GC!
+ 49.99 Mt
149.98x0.67=
-
99.98 Mt
(100+49.99) 33.33% Oversize
10 GC
Re-circulate
149.99x0.33 =
to GC!
+ 50.00 Mt
133.33x0.67=
-
99.99 Mt
(100+50.00) 33.33% Oversize
10 GC
Re-circulate
150.00x0.33 =
to GC!
+ 50.00 Mt
150.00x0.67=
-
100.00 Mt
Total Feed
• Total feed is now computed as:
Total Feed  Fresh Feed  Circulatin g Load

 100Mt  50Mt
 150Mt
Total Feed
• May also be computed using the formula:
F F
Total Feed  
 Ri  1 - R j 
1 - 
 % Eff 
Where: F = Initial Feed
Ri = %Oversize of Crusher Product
%Eff = % Screen Efficiency
Rj = Ri / %Eff
Total Feed
• Using the formula, total feed may be
computed as:
F F
Total Feed  
1 - R j  1 - R i 
 %Eff 
100Mt 100Mt
 
 0.3  0.67
1  
 0.9 
 150Mt

Panunumpa NG Propesyonal

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Panunumpa NG Propesyonal

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Circulating Load Calculations

Screen Efficiency Factors

• Considered for closed-circuit

Total Feed  Fresh Feed  Circulatin g Load

• For the given problem, 30Mt

• Thus, we can see that:

Total Feed  Fresh Feed  Circulatin g Load

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