About the Cyclosim_Single Spreadsheet ...

Scope :

The Cyclosim_Single spreadsheet was designed to simulate the response of a hydrocyclone (or cluster of hydrocyclones)
of any given geometry, operating in open circuit under known inlet conditions.

Theoretical Framework :

The technical literature contains various Empirical Correlations, attempting to describe the response of a hydrocyclone in
front of a given set of operating conditions. Examples of these formulations are the work of T. C. Rao and A. J. Lynch from
Australia ("Modelling and Scale-up of Hydrocyclone Classifiers", XI Int. Min. Proc. Congress II, 1-25, 1975. Also in the book
Mineral Crushing and Grinding Circuits, Elsevier, New York, 1977), the research of L. R. Plitt in the USA ("A Mathematical
Model for the Hydrocyclone Classifier", CIM Bulletin, p.114, December 1976) and the correlations proposed by CIMM in
Chile (as reported by L. Gutiérrez and J. E. Sepúlveda, Dimensionamiento y Optimización de Plantas Concentradoras
Mediante Técnicas de Modelación Matemática, CIMM Special Publication, 1986). Being all very similar in nature, the latter
has been incorporated to Cyclosim_Single.

In all of the above formulations, the Partition or Classification Function of the cyclones (defined as the fractional weight
recovery to the cyclone underflow of any given size fraction in the feed; badly called Classification Efficiency) is
decomposed into two effects : a direct feed slurry short-circuit to the underflow and the ideal (or corrected) classification of
a hypothetical cyclone with no short-circuit at all, in such a way that :

Ei = Bpf + (1 - Bpf ) Eic

where,

Ei = actual cyclone classification efficiency (fractional partition) for particles of size d i.

Eic = corrected cyclone classification efficiency for particles of size d i, excluding the feed slurry short
circuit.
Bpf = fraction of the feed slurry that short-circuits the cyclone directly to the underflow.

The CIMM Model - essentially a variation of Plitt's Model - consists of the following 5 empirical correlations derived back
in 1983, from a fairly extensive experimental program under a wide range of cyclone geometries and operating conditions :

Correlation 1 : Cyclone Feed Pressure

Q1.46 exp( -7.63+ 10.79  2 )

H = a1 ______________________________________________

(DC)0.20 h0.15 (DI)0.51 (DO)1.65 (DU)0.53

where,

H = cyclone feed pressure, expressed in equivalent ft of feed slurry.

Q = volumetric cyclone feedrate, m 3/hr.
 = fraction of solids in the cyclone feed, by volume.

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Moly-Cop Tools / 450474962.xls 12/04/2019 / 20:03:36
 DC = cyclone diameter, in.
h = cyclone free height, defined as the distance from the bottom of the vortex finder down to the top
of the apex, in.
DI = cyclone feed inlet diameter (circle area equivalent if the inlet is rectangular), in.
DO = cyclone vortex finder diameter, in.
DU = cyclone apex diameter, in.

and a1 is an application dependent constant to be determined from at least one set of actual plant data using Spreadsheets
Cyclobal_Single or Ballbal_Direct or Ballbal_Reverse, depending on the available data.

Correlation 2 : Corrected Cut Size, d50c.

The corrected cut size d50c is defined as that particular particle size that would be split on a 50:50 weight ratio between the
overflow and underflow streams, based on the corrected efficiency curve :

(DC)0.44 (DI)0.58 (DO)1.91 exp( 11.12  )

d50
c
= a2 _______________________________________________

(DU)0.80 h0.37 Q0.44 (  s - 1 )0.5

where a2 is also an application dependent constant to be determined in a similar fashion as a 1.

Correlation 3 : Flow Split.

Q u
h0.19 (DU/DO)2.64 exp( -4.33+8.77 2 )
S = ______
= a3 _________________________________________________

Qo H 0.54 (DC)0.38

where the flow split S (also referred to as the "wet" circulating load) is the ratio of the underflow volumetric flowrate to the
overflow flowrate of slurry. Again a 3 is to be determined as a1 and a2.

Correlation 4 : Corrected Classification Efficiency.

Eic = 1 - exp [ - 0.693 (di/d50c)m ]

where the so called Plitt's Parameter m, has been correlated as follows,

m = exp [ a4 - 1.58 S/(S+1) ] [ (DC)2 h / Q ]0.15

and a4 is to be determined as a1, a2 and a3.

Correlation 5 : Slurry Short-Circuit.

The CIMM model contributed a 5th correlation relating (and so differentiating) the fractional slurry by-pass to the underflow
(Bpf) with the water by-pass (Bpw), through a direct proportionality expression :

Bpf = l Bpw

Moly-Cop Tools / 450474962.xls 12/04/2019 / 20:03:36

where l is the 5th application dependent constant, like the previous a 1, a2, a3 and a4 and where the water by-pass Bpw may
be obtained from :

S/(S+1) -  R s
c

Bpw = ____________________________

1 -  [ 1 - l(1-Rsc)]

with Rsc - the hypothetical total underflow weight recovery of solids if the actual cyclone efficiency was to be the corrected
efficiency - given by :

n
R s
c
=  fi Eic
i=1

and fi represents the weight fraction of particles of size di in the cyclone feed stream.

The computation algorithm involves the direct evaluation of the first 4 correlations for H, d 50c, S and m to calculate the
corrected partition curve Eic for every particle size di. Then proceeds with the calculation of R sc to obtain Bpf, Bpw and finally,
the desired actual partition function Ei for every particle size di. After these preliminary steps, the computation of the
detailed mass balance around the cyclones is fairly straight forward.

Data Input :

All data required by the model must be defined in each corresponding unprotected white background cell 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.

Simulation results are summarized in the Reports worksheet.

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.

Moly-Cop Tools / 450474962.xls 12/04/2019 / 20:03:36

mulate the response of a hydrocyclone (or cluster of hydrocyclones)
nown inlet conditions.

elations, attempting to describe the response of a hydrocyclone in

these formulations are the work of T. C. Rao and A. J. Lynch from
sifiers", XI Int. Min. Proc. Congress II, 1-25, 1975. Also in the book
ork, 1977), the research of L. R. Plitt in the USA ("A Mathematical
14, December 1976) and the correlations proposed by CIMM in
, Dimensionamiento y Optimización de Plantas Concentradoras
pecial Publication, 1986). Being all very similar in nature, the latter

cation Function of the cyclones (defined as the fractional weight

ion in the feed; badly called Classification Efficiency) is
ircuit to the underflow and the ideal (or corrected) classification of
a way that :

Bpf ) Eic

cy (fractional partition) for particles of size d i.

ency for particles of size d i, excluding the feed slurry short

ircuits the cyclone directly to the underflow.

el - consists of the following 5 empirical correlations derived back

der a wide range of cyclone geometries and operating conditions :

+ 10.79  2 )
________________

(DO)1.65 (DU)0.53

n equivalent ft of feed slurry.

by volume.

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Moly-Cop Tools / 450474962.xls 12/04/2019 / 20:03:36
distance from the bottom of the vortex finder down to the top

rea equivalent if the inlet is rectangular), in.

mined from at least one set of actual plant data using Spreadsheets
e, depending on the available data.

article size that would be split on a 50:50 weight ratio between the
efficiency curve :

exp( 11.12  )
______________

 s - 1 )0.5

e determined in a similar fashion as a 1.

64
exp( -4.33+8.77 2 )
___________________________

0.54
(DC)0.38

lating load) is the ratio of the underflow volumetric flowrate to the

as a1 and a2.

ated as follows,

(DC)2 h / Q ]0.15

and so differentiating) the fractional slurry by-pass to the underflow

rtionality expression :

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he previous a 1, a2, a3 and a4 and where the water by-pass Bpw may

c
)]

y of solids if the actual cyclone efficiency was to be the corrected

i
in the cyclone feed stream.

of the first 4 correlations for H, d 50c, S and m to calculate the

en proceeds with the calculation of Rsc to obtain Bpf, Bpw and finally,
size di. After these preliminary steps, the computation of the
ght forward.

orresponding unprotected white background cell of the here

contain the results of the corresponding formulas there defined

sheet.

ief comments inserted in each relevant cell, rendering the whole

Moly-Cop Tools / 450474962.xls 12/04/2019 / 20:03:36

Moly-Cop Tools TM

CYCLOSIM
Simulation N° 1

Remarks Base Case Example

# of Cyclones Geometry, inches

Cyclones Diameter Height Inlet Vortex Apex
10 20.00 75.00 3.50 7.50 3.67

Operating Conditions : Ore Density, ton/m3 2.80

Cyclone Feed Conditions

Dry Tons Water Slurry Flow Density % Solids % Solids
ton/hr m3/hr ton/hr m3/hr ton/m3 (by volume) (by weight)
1622.84 986.16 2609.01 1565.75 1.666 37.02 62.20

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse)

a1 a2 a3 a4 l
9.680 1.401 54.964 0.523 0.950
9.680 1.401 54.964 0.523 0.950 Suggested Default Values

Feed Size Distribution :

i Mesh Opening Mid-Size ton/hr % Ret % Pass

1 1.05 25400 30206 0.00 0.00 100.00
2 0.742 19050 21997 0.00 0.00 100.00
3 0.525 12700 15554 18.17 1.12 98.88
4 0.371 9500 10984 41.49 2.56 96.32
5 3 6700 7978 40.76 2.51 93.81
6 4 4750 5641 37.01 2.28 91.53
7 6 3350 3989 38.53 2.37 89.16
8 8 2360 2812 44.14 2.72 86.44
9 10 1700 2003 51.21 3.16 83.28
10 14 1180 1416 66.98 4.13 79.16
11 20 850 1001 78.83 4.86 74.30
12 28 600 714 100.61 6.20 68.10
13 35 425 505 122.86 7.57 60.53
14 48 300 357 142.11 8.76 51.77
15 65 212 252 143.62 8.85 42.92
16 100 150 178 125.60 7.74 35.18
17 150 106 126 98.97 6.10 29.08
18 200 75 89 73.25 4.51 24.57
19 270 53 63 53.99 3.33 21.24
20 400 38 45 38.98 2.40 18.84
21 -400 0 19 305.76 18.84 0.00

Total 1622.84 100.00

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 Moly-Cop Tools TM
Sample N° 1

CYCLOSIM
Hydrocyclone Simulator

Remarks : Base Case Example

Number of Cyclones : 10 Operating Conditions :

Cyclone Dimensions, in : Feed Flowrate, m3/hr 1565.7
Diameter 20.00 Pressure, psi 8.0
Height 75.00 D50 (corr.), microns 179.8
Inlet 3.50 Water By-Pass, % 39.2
Vortex 7.50 Solids By-Pass, % 37.2
Apex 3.67 Plitt's Parameter 1.62
Ore Density, ton/m3 2.80 Circulating Load, % 306

Size Distributions, % Passing Classifier Efficiency

Mesh Opening Mid-Size Feed U'flow O'flow Actual Corrected

1.05 25400 30206 100.00 100.00 100.00 1.000 1.000

0.742 19050 21997 100.00 100.00 100.00 1.000 1.000
0.525 12700 15554 98.88 98.51 100.00 1.000 1.000
0.371 9500 10984 96.32 95.12 100.00 1.000 1.000
3 6700 7978 93.81 91.79 100.00 1.000 1.000
4 4750 5641 91.53 88.76 100.00 1.000 1.000
6 3350 3989 89.16 85.61 100.00 1.000 1.000
8 2360 2812 86.44 82.00 100.00 1.000 1.000
10 1700 2003 83.28 77.82 100.00 1.000 1.000
14 1180 1416 79.16 72.34 100.00 1.000 1.000
20 850 1001 74.30 65.89 100.00 1.000 1.000
28 600 714 68.10 57.67 99.97 0.999 0.998
35 425 505 60.53 47.79 99.49 0.984 0.975
48 300 357 51.77 37.06 96.76 0.923 0.878
65 212 252 42.92 27.54 89.95 0.810 0.698
100 150 178 35.18 20.52 80.00 0.683 0.495
150 106 126 29.08 15.87 69.49 0.575 0.323
200 75 89 24.57 12.89 60.28 0.498 0.200
270 53 63 21.24 10.92 52.82 0.447 0.119
400 38 45 18.84 9.59 47.13 0.417 0.071
-400 0 19 0.383 0.018

D80, microns 1273 2022 150.0

Ore, ton/hr 1622.8 1222.9 399.9 Classifier Constants

Water, m3/hr 986.2 386.3 599.9
Slurry, ton/hr 2609.0 1609.2 999.8 a1 9.680
Slurry, m3/hr 1565.7 823.0 742.7 a2 1.401
Slurry Dens., ton/m3 1.666 1.955 1.346 a3 54.964
% Solids (by volume) 37.0 53.1 19.2 a4 0.523
% Solids (by weight) 62.2 76.0 40.0 l 0.950

Moly-Cop Tools / 450474962.xls Page 10 12/04/2019 / 20:03:36

Cyclones Geometry, inches
Diameter Height Inlet Vortex Apex
20.0 75.0 3.50 7.50 3.67

Operating Conditions :
ton/m3 (by volume) s ton/hr m3/hr
156.57 0.370 2.80 162.28 98.62

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse)

a1 a2 a3 a4 l
9.680 1.401 54.964 0.523 0.950

Calculations

Correlation 1. Cyclone Feed Pressure, ft.

H 11.05621

Correlation 2. Corrected Cut Size, microns.

d50c 179.809

Correlation 3. Slurry Split.

S 1.108145

Correlation 4. Classification Efficiency.

Water Water
m (Plitt) Rsc Bpw Bpf U'flow % Sol. O'flow % Sol.
1.61731006 0.607512 0.39170013 0.37211513 38.62795 75.99547 59.98818 40.0005

Fraction Tyler Opening di* Feed Ei Rsc,i Ei Underflow Overflow

# Mesh micr. micr. ton % Ret. (corr) = fi Eic (real) ton % Ret. ton % Ret.
 1 1.05 25400 30206 0.00 0.00 1.000 0.000 1.000 0.00 0.00 0.00 0.00
2 0.742 19050 21997 0.00 0.00 1.000 0.000 1.000 0.00 0.00 0.00 0.00
3 0.525 12700 15554 1.82 1.12 1.000 0.011 1.000 1.82 1.49 0.00 0.00
4 0.371 9500 10984 4.15 2.56 1.000 0.026 1.000 4.15 3.39 0.00 0.00
5 3 6700 7978 4.08 2.51 1.000 0.025 1.000 4.08 3.33 0.00 0.00
6 4 4750 5641 3.70 2.28 1.000 0.023 1.000 3.70 3.03 0.00 0.00
7 6 3350 3989 3.85 2.37 1.000 0.024 1.000 3.85 3.15 0.00 0.00
8 8 2360 2812 4.41 2.72 1.000 0.027 1.000 4.41 3.61 0.00 0.00
9 10 1700 2003 5.12 3.16 1.000 0.032 1.000 5.12 4.19 0.00 0.00
10 14 1180 1416 6.70 4.13 1.000 0.041 1.000 6.70 5.48 0.00 0.00
11 20 850 1001 7.88 4.86 1.000 0.049 1.000 7.88 6.45 0.00 0.00
12 28 600 714 10.06 6.20 0.998 0.062 0.999 10.05 8.22 0.01 0.03
13 35 425 505 12.29 7.57 0.975 0.074 0.984 12.09 9.89 0.19 0.49
14 48 300 357 14.21 8.76 0.878 0.077 0.923 13.12 10.73 1.09 2.73
15 65 212 252 14.36 8.85 0.698 0.062 0.810 11.64 9.52 2.72 6.81
16 100 150 178 12.56 7.74 0.495 0.038 0.683 8.58 7.02 3.98 9.95
17 150 106 126 9.90 6.10 0.323 0.020 0.575 5.69 4.65 4.21 10.52
18 200 75 89 7.32 4.51 0.200 0.009 0.498 3.64 2.98 3.68 9.20
19 270 53 63 5.40 3.33 0.119 0.004 0.447 2.41 1.97 2.99 7.46
20 400 38 45 3.90 2.40 0.071 0.002 0.417 1.62 1.33 2.27 5.69
21 -400 0 19 30.58 18.84 0.018 0.003 0.383 11.73 9.59 18.85 47.13

TOTAL 162.28 100.00 0.608 122.29 100.00 39.99 100.00

Circulating Load : 3.06