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Moly-Cop Tools, Version 3.

0
About the BallBal_Direct Spreadsheet ...

Scope :

The BallBal_Direct 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 Direct 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
hydrocyclones, for particles of size di :

fiCF CF = fiU U + fiO O ??? , for i = 1,n

will never be satisfied. In the above expression CF, U and O represent the mass flowrate of solids in the cyclones
feed, underflow and overflow streams, respectively. Similarly, fiCF, fiU and fiO represent the fraction of those total
respective streams corresponding to particles of size di.

The Ballbal_Direct routine allows for the calculation of a whole new set of corresponding adjusted or fitted values
fiCF, fiU and fiO, such that the objective functions :

f i = [ wCF (fiCF - fiCF)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 :

fiCF CF = fiU U + fiO O , for i = 1,n

where wCF, wU and wO are user-defined weighting factors included to represent the relative quality and reliability of
the samples from each of the 3 streams and the mass flowrates CF, U and O are calculated as :

CF = F (1 + CL)
U = F (CL)
O = F

where F is the dry Fresh Feedrate of solids to the grinding section and the Circulating Load (CL) is estimated by
:

CL = { usd S [(fiO - fiCF) / (fiCF - fiU)] + ufs (1/fSO - 1/fSCF) / (1/fSCF -1/fSU) } / (usd + ufs)
all i

where fsCF, fsU and fsO are the weight fractions of total solids in the cyclones feed, 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 3 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. A statistically sound weighting factor may be calculated as
100/(% error)2;

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Moly-Cop Tools / 458527263.xlsx Page 2 02/05/2020 / 18:23:30
Moly-Cop Tools, Version 3.0
About the Ballbal_Direct Spreadsheet ...

where (% error) corresponds to the combined sampling and measuring error percentage. Weighting factors must
never be set equal to zero.

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 error objective function with respect to
parameters Bpf, d50c and m.

Finally, the size distributions for the remaining streams of the circuit (fresh feed, mill feed and mill discharge) are
calculated on the basis of the adjusted values so obtained.

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 formula 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 B pf, 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 pressurized 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 E23 in Control_Panel and then, from the Tools Menu,
select Solver ..., then Min and then By Changing any combination of Cells C21:F21. 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.

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.

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Moly-Cop Tools / 458527263.xlsx Page 4 02/05/2020 / 18:23:30
Moly-Cop Tools TM
(Version 3.0)

Ballbal_Direct : MASS BALANCE CLOSURE AROUND A BALL MILL GRINDING CIRCUIT

Sample N° 1
100
Weighting Factors :
Streams :
Fresh Feed 0
Mill Discharge 1

% Passing
Cyclone Feed 1
Cyclone U'flow 1
Cyclone O'flow 1

Size Distributions 1 10
% Solids 1

Initial Guesses :
Bpf Bpc d50c m
Mill Discharge
0.372 0.000 179.8 1.619 4 Cyclone U'flow
Cyclone O'flow
Column F
Obj. Function : 0.005 Column I
Column J
Classifier Constants : Fresh Feed

a1 9.68 1
a2 1.401 10 100 1000 10000
a3 54.95 Particle Size, microns
a4 0.524
l 0.950 Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.

Moly-Cop Tools / 458527263.xlsx 02/05/2020 / 18:23:30


Moly-Cop Tools TM
(Version 3.0)
BALLBAL : Mass Balance Closure around a Ball Mill Grinding Circu

Circuit Type DIRECT

Remarks Base Case Example

Mill Dimensions and Operating Conditions 3348 Balls


Eff. Diam. Eff. Length Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, (°) 536 Slurry
18.5 22.0 72.0 38.00 38.00 100.00 35.0 3885 Net Power
rpm 12.82 10.0 % Losses
4316 Gross kW
Cyclone Dimensions (inches) and Operating Pressure (psi)
Number Diameter Height Inlet Vortex Apex psi
10 20.0 75.0 3.50 7.50 3.67 7.98
Default Values: 60.0 5.0 7.0 3.5

EXPERIMENTAL SIZE DISTRIBU


Fresh Feed Mill Discharge Cyclone Feed
i Mesh Opening Mid-Size ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained

1 1.05 25400 100.00 100.00


2 0.742 19050 21997 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00
3 0.525 12700 15554 20.00 5.00 95.00 13.69 1.12 98.88 18.17 1.12
4 0.371 9500 10984 66.40 16.60 78.40 31.26 2.56 96.32 41.49 2.56
5 3 6700 7978 56.28 14.07 64.33 30.71 2.51 93.81 40.76 2.51
6 4 4750 5641 41.32 10.33 54.00 27.88 2.28 91.53 37.01 2.28
7 6 3350 3989 33.36 8.34 45.66 29.03 2.37 89.16 38.53 2.37
8 8 2360 2812 27.36 6.84 38.82 33.26 2.72 86.44 44.14 2.72
9 10 1700 2003 21.64 5.41 33.41 38.59 3.16 83.28 51.21 3.16

Moly-Cop Tools / 458527263.xlsx 02/05/2020 / 18:23:30


10 14 1180 1416 20.40 5.10 28.31 50.47 4.13 79.16 66.98 4.13
11 20 850 1001 15.60 3.90 24.41 59.40 4.86 74.30 78.83 4.86
12 28 600 714 14.16 3.54 20.87 75.81 6.20 68.10 100.61 6.20
13 35 425 505 12.04 3.01 17.86 92.58 7.57 60.53 122.86 7.57
14 48 300 357 10.36 2.59 15.27 107.08 8.76 51.77 142.11 8.76
15 65 212 252 8.84 2.21 13.06 108.22 8.85 42.92 143.62 8.85
16 100 150 178 7.52 1.88 11.18 94.65 7.74 35.18 125.60 7.74
17 150 106 126 6.48 1.62 9.56 74.57 6.10 29.08 98.97 6.10
18 200 75 89 5.52 1.38 8.18 55.19 4.51 24.57 73.25 4.51
19 270 53 63 4.72 1.18 7.00 40.68 3.33 21.24 53.99 3.33
20 400 38 45 3.40 0.85 6.15 29.37 2.40 18.84 38.98 2.40
21 -400 0 19 24.60 6.15 0.00 230.40 18.84 0.00 305.76 18.84
Totals 400.00 100.00 1222.84 100.00 1622.84 100.00

% Solids 95.00 72.00


Slurry Density, ton/m3 2.569 1.862
Weighting Factor 0.000 1.000

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Closure around a Ball Mill Grinding Circuit

Sample N° 1

Charge Mill Charge Weight, tons Apparent


Volume, Ball Slurry Density
m3 Charge Interstitial Excess ton/m3
63.76 296.48 47.48 0.00 5.395

Feedrate, ton/hr (dry) 400.0

Ore Density, ton/m3 2.80


Balls Density, ton/m3 7.75

EXPERIMENTAL SIZE DISTRIBUTIONS


Cyclone Feed Cyclone U'flow Cyclone O'flow
% Passing ton/hr % Retained % Passing ton/hr % Retained % Passing

100.00 100.00 100.00


100.00 0.00 0.00 100.00 0.00 0.00 100.00
98.88 18.17 1.49 98.51 0.00 0.00 100.00
96.32 41.49 3.39 95.12 0.00 0.00 100.00
93.81 40.76 3.33 91.79 0.00 0.00 100.00
91.53 37.01 3.03 88.76 0.00 0.00 100.00
89.16 38.53 3.15 85.61 0.00 0.00 100.00
86.44 44.14 3.61 82.00 0.00 0.00 100.00
83.28 51.21 4.19 77.81 0.00 0.00 100.00

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79.16 66.98 5.48 72.34 0.00 0.00 100.00
74.30 78.83 6.45 65.89 0.00 0.00 100.00
68.10 100.51 8.22 57.67 0.10 0.02 99.97
60.53 120.92 9.89 47.78 1.94 0.49 99.49
51.77 131.20 10.73 37.05 10.90 2.73 96.76
42.92 116.40 9.52 27.54 27.23 6.81 89.96
35.18 85.79 7.02 20.52 39.81 9.95 80.00
29.08 56.90 4.65 15.87 42.06 10.52 69.49
24.57 36.44 2.98 12.89 36.81 9.20 60.29
21.24 24.14 1.97 10.91 29.86 7.46 52.82
18.84 16.23 1.33 9.59 22.75 5.69 47.13
0.00 117.22 9.59 0.00 188.54 47.13 0.00
1222.84 100.00 400.00 100.00

62.20 76.00 40.00


1.666 1.955 1.346
1.000 1.000 1.000

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Moly-Cop Tools TM
(Version 3.0)
Sample N° 1

Remarks Base Case Example

40.00 % Solids
60.29 % - Size 18
psi 7.98 150.0 P80

# of Cyclones 10
Vortex 7.50 Circ. Load 305.73
Apex 3.67 0.372 Bpf m3/hr 1566
0.392 Bpw

% Solids 76.00

Water,
m3/hr 355.1
ton/hr 400.0 Water, 223.9
F80 9795 m3/hr

Gross kW 4316.1
kWh/ton 10.79 % Balls 38.00
Wio 15.08 % Critical 72.00
% Solids 72.00

% Solids 62.20

Moly-Cop Tools / 458527263.xlsx / Flowsheet 02/05/2020 / 18:23:30


Moly-Cop ToolsTM, Version 3.0 Sample: 1
BALLBAL
Grinding Circuit Mass Balance Estimator

Remarks: Base Case Example

CIRCUIT MASS BALANCE


Configuration : DIRECT

Fresh Mill Mill Sump Cyclone Cyclone Cyclone


Feed Feed Discharge Water Feed U'flow O'flow
Ore, ton/hr 400.0 1622.9 1622.9 0.0 1622.9 1222.9 400.0
Water, m3/hr 21.1 407.3 631.1 355.1 986.2 386.2 600.0
Slurry, ton/hr 421.1 2030.2 2254.1 355.1 2609.2 1609.2 1000.0
Slurry, m3/hr 163.9 986.9 1210.8 355.1 1565.8 823.0 742.9
Slurry Dens., ton/m3 2.569 2.057 1.862 1.000 1.666 1.955 1.346
% Solids (by volume) 87.2 58.7 47.9 0.0 37.0 53.1 19.2
% Solids (by weight) 95.0 79.9 72.0 0.0 62.2 76.0 40.0

Particle Size Distributions (Cummulative % Passing)


i Mesh Opening

1 1.05 25400 100.00 100.00 100.00 0.00 100.00 100.00 100.00


2 0.742 19050 100.00 100.00 100.00 0.00 100.00 100.00 100.00
3 0.525 12700 95.00 97.65 98.88 0.00 98.88 98.51 100.00
4 0.371 9500 78.40 91.00 96.32 0.00 96.32 95.12 100.00
5 3 6700 64.33 85.02 93.81 0.00 93.81 91.79 100.00
6 4 4750 54.00 80.20 91.53 0.00 91.53 88.76 100.00
7 6 3350 45.66 75.77 89.16 0.00 89.16 85.61 100.00
8 8 2360 38.82 71.36 86.44 0.00 86.44 82.00 100.00
9 10 1700 33.41 66.87 83.28 0.00 83.28 77.82 99.99
10 14 1180 28.31 61.49 79.16 0.00 79.16 72.34 99.99
11 20 850 24.41 55.67 74.30 0.00 74.30 65.89 99.99
12 28 600 20.87 48.60 68.10 0.00 68.10 57.68 99.96
13 35 425 17.86 40.41 60.53 0.00 60.53 47.79 99.48
14 48 300 15.27 31.69 51.77 0.00 51.77 37.06 96.76
15 65 212 13.06 23.97 42.92 0.00 42.92 27.54 89.96
16 100 150 11.18 18.22 35.18 0.00 35.18 20.52 80.01
17 150 106 9.56 14.31 29.08 0.00 29.08 15.87 69.49
18 200 75 8.18 11.73 24.57 0.00 24.57 12.89 60.29
19 270 53 7.00 9.95 21.24 0.00 21.24 10.91 52.82
20 400 38 6.15 8.74 18.84 0.00 18.84 9.59 47.13

D80, microns 9795 4679 1273 0 1273 2021 150.0

Specific Energy Consumption : 10.79 KWH/ton (Gross)


Operational Work Index : 15.08 KWH/ton

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Moly-Cop ToolsTM, Version 3.0 Sample: 1
BALLBAL
Grinding Circuit Mass Balance Estimator

Remarks: Base Case Example

CLASSIFIERS PERFORMANCE

Number of Cyclones : 10 Operating Conditions :


Cyclone Dimensions, in : Feed Flowrate, m3/hr 1565.8
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

Mass Balance around the Classifiers

Size Distributions, % Passing Classifier Efficiency


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

1 1.05 25400 21997 100.00 100.00 100.00 1.000 1.000


2 0.742 19050 15554 100.00 100.00 100.00 1.000 1.000
3 0.525 12700 10984 98.88 98.51 100.00 1.000 1.000
4 0.371 9500 7978 96.32 95.12 100.00 1.000 1.000
5 3 6700 5641 93.81 91.79 100.00 1.000 1.000
6 4 4750 3989 91.53 88.76 100.00 1.000 1.000
7 6 3350 2812 89.16 85.61 100.00 1.000 1.000
8 8 2360 2003 86.44 82.00 100.00 1.000 1.000
9 10 1700 1416 83.28 77.82 99.99 1.000 1.000
10 14 1180 1001 79.16 72.34 99.99 1.000 1.000
11 20 850 714 74.30 65.89 99.99 0.999 0.998
12 28 600 505 68.10 57.68 99.96 0.984 0.975
13 35 425 357 60.53 47.79 99.48 0.923 0.878
14 48 300 252 51.77 37.06 96.76 0.811 0.698
15 65 212 178 42.92 27.54 89.96 0.683 0.495
16 100 150 126 35.18 20.52 80.01 0.575 0.323
17 150 106 89 29.08 15.87 69.49 0.497 0.200
18 200 75 63 24.57 12.89 60.29 0.447 0.119
19 270 53 45 21.24 10.91 52.82 0.416 0.071
20 400 38 19 18.84 9.59 47.13 0.383 0.018

Ore, ton/hr 1622.9 1222.9 400.0 Classifier Constants


Water, m3/hr 986.2 386.2 600.0 a1 9.680
Slurry, ton/hr 2609.2 1609.2 1000.0 a2 1.401
Slurry, m3/hr 1565.8 823.0 742.9 a3 54.950
Slurry Dens., ton/m3 1.666 1.955 1.346 a4 0.524
% Solids (by volume) 37.0 53.1 19.2 l 0.950
% Solids (by weight) 62.2 76.0 40.0 Bpc 0.000

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Moly-Cop ToolsTM, Version 3.0 Sample: 1
BALLBAL
Grinding Circuit Mass Balance Estimator

Remarks: Base Case Example

BALL MILL PERFORMANCE

Eff. Diameter, ft 18.5 Mill Power, kW (Gross) 4316


Eff. Length, ft 22.0 Mill Power, kW (Net) 3885
Speed, % Critical 72.0 Throughput, ton/hr 1622.9
App. Density, ton/m3 5.39 % Solids (by weight) 79.9
Charge Level, % 38.0 Sp. Energy, KWH/ton 2.66
Balls Filling, % 38.0 Reduction Ratio 3.67
Lift Angle, (°) 35.0 Arbiter's Flow Number 2.47

Size Distributions
Mill Mill
i Mesh Opening Mid-Size Feed Discharge

1 1.05 25400 21997 100.00 100.00


2 0.742 19050 15554 100.00 100.00
3 0.525 12700 10984 97.65 98.88
4 0.371 9500 7978 91.00 96.32
5 3 6700 5641 85.02 93.81
6 4 4750 3989 80.20 91.53
7 6 3350 2812 75.77 89.16
8 8 2360 2003 71.36 86.44
9 10 1700 1416 66.87 83.28
10 14 1180 1001 61.49 79.16
11 20 850 714 55.67 74.30
12 28 600 505 48.60 68.10
13 35 425 357 40.41 60.53
14 48 300 252 31.69 51.77
15 65 212 178 23.97 42.92
16 100 150 126 18.22 35.18
17 150 106 89 14.31 29.08
18 200 75 63 11.73 24.57
19 270 53 45 9.95 21.24
20 400 38 19 8.74 18.84

D80, microns 4679 1273

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C

Number of Cyclones 10
Classifier Dimensions, inches.
DC h DI DO DU
20 75 3.5 7.5 3.6695076
Classifier Constants
a1 a2 a3 a4 l Cyclone Cyclone Cyclone
9.6796047 1.4010849 54.949977 0.5242022 0.9501479 Feed U'flow O'flow
Circulating Load, CL 3.0573485 Solids, tons 162.28 122.29 39.99766
Slurry Split, S 1.107862 Water, m3/hr 98.62 38.62 60.00
Cyclone Pressure, ft 11.056209 Slurry, tons 260.90058 160.90643 99.994149
Cyclone Pressure, lb/in2 7.98 Slurry, m3/hr 156.57487 82.293502 74.281368
Corrected Cut Size, d50c, microns 179.77747 Solids Density, ton/m3 2.8 2.8 2.8
Water By-Pass 0.3916159 Slurry Density, ton/m3 1.6662992 1.9552751 1.3461538
Fines By-Pass 0.3720931 % Solids (by volume) 37.016623 53.070838 19.230769
Coarse By-Pass 8.909E-05 % Solids (by weight) 62.20 76.00 40.00
Plitt's Parameter 1.6194549
ton/hr (model) % Retained (model)
Opening Mid-Size Classifier Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone
Efficiency Feed U'flow O'flow Feed U'flow O'flow

1 25400
2 19050 21997.045 0.9999109 0.00 0 0.00 0.00 0.00 0.00
3 12700 15554.26 0.9999109 18.17 18.17042 0.00 1.12 1.49 0.00
4 9500 10984.079 0.9999109 41.49 41.486354 0.00 2.56 3.39 0.00
5 6700 7978.095 0.9999109 40.76 40.752794 0.00 2.51 3.33 0.00
6 4750 5641.3651 0.9999109 37.01 37.002772 0.00 2.28 3.03 0.00
7 3350 3989.0475 0.9999109 38.53 38.52856 0.00 2.37 3.15 0.00
8 2360 2811.761 0.9999109 44.14 44.13137 0.00 2.72 3.61 0.00
9 1700 2002.9978 0.9999109 51.21 51.203579 0.00 3.16 4.19 0.00
10 1180 1416.3333 0.9999109 66.98 66.970237 0.01 4.13 5.48 0.00
11 850 1001.4989 0.9999022 78.83 78.820783 0.01 4.86 6.45 0.00
12 600 714.14284 0.9989377 100.61 100.49874 0.11 6.20 8.22 0.03
13 425 504.97525 0.9842449 122.86 120.92517 1.94 7.57 9.89 0.48
14 300 357.07142 0.9234551 142.11 131.22813 10.88 8.76 10.73 2.72
15 212 252.1904 0.8106073 143.62 116.42087 27.20 8.85 9.52 6.80
16 150 178.32555 0.6831044 125.60 85.800946 39.80 7.74 7.02 9.95

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17 106 126.0952 0.5749239 98.97 56.897383 42.07 6.10 4.65 10.52


18 75 89.162773 0.4973836 73.25 36.432284 36.82 4.51 2.98 9.20
19 53 63.047601 0.4469656 53.99 24.132288 29.86 3.33 1.97 7.47
20 38 44.877611 0.4164241 38.98 16.231539 22.75 2.40 1.33 5.69
21 0 19 0.3834187 305.76 117.2336 188.53 18.84 9.59 47.13

Total 1622.84 1222.87 399.98 100.00 100.00 100.00

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% Passing (model) % Passing (exp) (Weighted Error)^2


Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone
Feed U'flow O'flow Feed U'flow O'flow Feed U'flow O'flow
1 1 1
100.00 100.00 100.00 100.00 100.00 100.00
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
98.88 98.51 100.00 98.88 98.51 100.00 0.000 0.000 0.000
96.32 95.12 100.00 96.32 95.12 100.00 0.000 0.000 0.000
93.81 91.79 100.00 93.81 91.79 100.00 0.000 0.000 0.000
91.53 88.76 100.00 91.53 88.76 100.00 0.000 0.000 0.000
89.16 85.61 100.00 89.16 85.61 100.00 0.000 0.000 0.000
86.44 82.00 100.00 86.44 82.00 100.00 0.000 0.000 0.000
83.28 77.82 99.99 83.28 77.81 100.00 0.000 0.000 0.000
79.16 72.34 99.99 79.16 72.34 100.00 0.000 0.000 0.000
74.30 65.89 99.99 74.30 65.89 100.00 0.000 0.000 0.000
68.10 57.68 99.96 68.10 57.67 99.97 0.000 0.000 0.000
60.53 47.79 99.48 60.53 47.78 99.49 0.000 0.000 0.000
51.77 37.06 96.76 51.77 37.05 96.76 0.000 0.000 0.000
42.92 27.54 89.96 42.92 27.54 89.96 0.000 0.000 0.000
35.18 20.52 80.01 35.18 20.52 80.00 0.000 0.000 0.000

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29.08 15.87 69.49 29.08 15.87 69.49 0.000 0.000 0.000


24.57 12.89 60.29 24.57 12.89 60.29 0.000 0.000 0.000
21.24 10.91 52.82 21.24 10.91 52.82 0.000 0.000 0.000
18.84 9.59 47.13 18.84 9.59 47.13 0.000 0.000 0.000

Overall
0.000 0.000 0.000

Page 17

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