Moly-Cop Tools, Version 3.

0
About the CycloBal_Single Spreadsheet ...

Scope :

The CycloBal_Single spreadsheet was designed to compute the Size-by-Size Mass Balance around a Hydrocyclone
Classifier on the basis of actual plant measurements from any given existing installation.

Theoretical Framework :

Whenever actual data are collected in a plant environment, they will invariably be affected by natural experimental and
measurement errors, in such a way that - in the particular case of hydrocyclones - the basic mass balance equation for the
mass flowrate of particles of size di :

fiF F = fiU U + fiO O ??? , for i = 1,n

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

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

fi = [ wF (fiF - fiF)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 = fiU U + fiO O , for i = 1,n

where wF, 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 F, U and O are calculated as :

F = F
U = F [CL / (1 + CL)]
O = F / (1 + CL)

and the Circulating Load CL is estimated from :

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

where fsF, fsU and fsO are the weight fractions of total solids in the 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; where (% error) corresponds to
the combined sampling and measuring error percentage.

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 Moly-Cop Tools, Version 3.0
About the Cyclobal_Single Spreadsheet ...

The least-square minimization problem stated above may be linearized and solved through the Lagrange Multipliers
Method to obtain :

fiF F = fiF F - l/wF

fiU U = fiU U + l/wU
fiO O = fiO O + l/wO ; for n = 1, n

with the Lagrange multiplier l given by :

l = ( fiF F - fiU U + fiO O) / (1/wF + 1/wU + 1/wO)

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 the Plitt's Parameter, m.

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 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, on the Control_Panel worksheet, select the objective function Cell E22 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.

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Moly-Cop Tools / 469529190.xlsx 04/11/2020 / 01:34:30
may be linearized and solved through the Lagrange Multipliers

wF
/wU
l/wO ; for n = 1, n

1/wF + 1/wU + 1/wO)

d is achieved by imposing the condition that these values must

e : (see About ... in Cyclosim_Single)

- exp [ - 0.693 (di/d50c)m ])

ize a least-square objective function with respect to parameters Bpf,

ed in each corresponding unprotected white background cell -

ed Data_File worksheet. Gray background cells contain the results
rotected to avoid any accidental editing.

m is entered in the Control_Panel worksheet, where the user is

d m parameters (see About ... in Cyclosim_Single). The Bpc
e into account the possible short-circuit of coarse particles to the
yclones). Finally, the user must specify the relative weighting factors
plus the relative weighting factors for the size distribution and percent

, select the objective function Cell E22 and then, from the Tools
ing any combination of Cells C20:F20. Clicking on the Solve button

e any element of input data gets to be modified. Otherwise, the

orksheet.

as the option to save for later reference every analyzed data set by
uired Sample 1, Sample 2, etc. worksheets. For reprocessing these
le and re-run the Solver routine.

brief comments inserted in each relevant cell, rendering the whole

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Moly-Cop Tools / 469529190.xlsx 04/11/2020 / 01:34:30
 Moly-Cop Tools TM
(Version 3.0)
Cyclobal_Single : HYDROCYLONE MASS BALANCE CLOSURE

Sample N° 1
100
Weighting Factors :
Streams :
Cyclone Feed 1
Cyclone U'flow 1
Cyclone O'flow 1

% Passing
Size Distributions 1
% Solids 1

10

Initial Guesses :
Bpf Bpc d50c m
0.062 0.000 45.7 1.149 4

Obj. Function : 0.190 Cyclone Feed

Cyclone U'flow
Cyclone O'flow
Classifier Constants : Column E
Column F
a1 13.97 Column G
1
a2 0.468
10 100 1000 10000
a3 102.26
Particle Size, microns
a4 0.000
l 0.219

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 Moly-Cop Tools TM
(Version 3.0)
HYDROCYCLONE MASS BALANCE CLOSURE

Remarks Base Case Example Sample N° 1

Cyclone Dimensions, inches Ore Density, ton/m3 2.80

Number Diameter Height Inlet Vortex Apex Dry Feedrate, ton/hr 131.0
1 22.0 75.0 3.50 8.00 3.00 Volumetric Flow, m3/hr 149.7
Default Values: 66.0 5.50 7.70 4.00 Cyclones Pressure, psi 10.00

EXPERIMENTAL SIZE DISTRIBUTIONS

Cyclone Feed Cyclone U'flow Cyclone O'flow
i Mesh Opening Mid-Size ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained % Passing
1 1.05 25400 100.00 100.00 100.00
2 0.742 19050 21997 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
3 0.525 12700 15554 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
4 0.371 9500 10984 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
5 3 6700 7978 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
6 4 4750 5641 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
7 6 3350 3989 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
8 8 2360 2812 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
9 10 1700 2003 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
10 14 1180 1416 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
11 20 850 1001 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
12 28 600 714 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
13 35 425 505 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
14 48 300 357 4.30 3.29 96.71 4.28 4.30 95.70 0.00 0.00 100.00
15 65 212 252 41.15 31.41 65.30 40.68 40.90 54.80 0.22 0.70 99.30
16 100 150 178 19.93 15.22 50.08 19.20 19.30 35.50 0.63 2.00 97.30
17 150 106 126 13.04 9.95 40.13 11.64 11.70 23.80 1.36 4.30 93.00
18 200 75 89 9.87 7.53 32.60 7.66 7.70 16.10 2.21 7.00 86.00
19 270 53 63 4.96 3.79 28.81 3.18 3.20 12.90 1.80 5.70 80.30
20 400 38 45 9.63 7.35 21.46 5.17 5.20 7.70 4.51 14.30 66.00
21 -400 0 19 28.11 21.46 0.00 7.66 7.70 0.00 20.81 66.00 0.00
Totals 131.00 100.00 99.47 100.00 31.53 100.00

% Solids 56.00 78.00 30.00

Weighting Factor 1.000 1.000 1.000

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 Moly-Cop Tools TM
(Version 3.0)

CYCLOBAL Sample N° 1
Cyclone Mass Balance Closure

Remarks : Base Case Example

Number of Cyclones : 1 Operating Conditions :

Cyclone Dimensions, in : Feed Flowrate, m3/hr 148.9
Diameter 22.00 Pressure, psi 10.0
Height 75.00 D50 (corr.), microns 45.7
Inlet 3.50 Water By-Pass, % 28.5
Vortex 8.00 Solids By-Pass, % 6.2
Apex 3.00 Plitt's Parameter 1.15
Ore Density, ton/m3 2.80 Circulating Load, % 319

Size Distributions, % Passing Classifier Efficiency

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

1.05 25400 21997 100.00 100.00 100.00 1.000 1.000

0.742 19050 15554 100.00 100.00 100.00 1.000 1.000
0.525 12700 10984 100.00 100.00 100.00 1.000 1.000
0.371 9500 7978 100.00 100.00 100.00 1.000 1.000
3 6700 5641 100.00 100.00 100.00 1.000 1.000
4 4750 3989 100.00 100.00 100.00 1.000 1.000
6 3350 2812 100.00 100.00 100.00 1.000 1.000
8 2360 2003 100.00 100.00 100.00 1.000 1.000
10 1700 1416 100.00 100.00 100.00 1.000 1.000
14 1180 1001 100.00 100.00 100.00 1.000 1.000
20 850 714 100.00 100.00 100.00 1.000 1.000
28 600 505 100.00 100.00 100.00 1.000 1.000
35 425 357 100.00 100.00 100.00 0.999 0.999
48 300 252 96.73 95.70 99.99 0.993 0.993
65 212 178 65.43 54.86 99.10 0.966 0.964
100 150 126 50.26 35.62 96.92 0.899 0.892
150 106 89 40.33 23.89 92.70 0.789 0.775
200 75 63 32.80 16.08 86.06 0.656 0.633
270 53 45 29.00 12.81 80.60 0.524 0.493
400 38 19 21.63 7.73 65.91 0.272 0.223

D80, microns 253 268 52.4

Ore, ton/hr 131.0 99.7 31.3 Classifier Constants

Water, m3/hr 102.1 29.1 73.1 a1 13.966
Slurry, ton/hr 233.1 128.8 104.4 a2 0.468
Slurry, m3/hr 148.9 64.7 84.2 a3 102.262
Slurry Dens., ton/m3 1.566 1.991 1.239 a4 0.000
% Solids (by volume) 31.4 55.1 13.3 l 0.219
% Solids (by weight) 56.2 77.4 30.0 Bpc 0.000

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 Moly-Cop Tools TM
(Version 3.0)

CYCLOBAL Sample N° 1
Raw Experimental Data

Remarks : Base Case Example

Number of Cyclones : 1 Operating Conditions :

Cyclone Dimensions, in : Feed Flowrate, m3/hr 149.7
Diameter 22.00 Pressure, psi 10.0
Height 75.00
Inlet 3.50
Vortex 8.00
Apex 3.00
Ore Density, ton/m3 2.80 Circulating Load, % 316

Size Distributions, % Passing

EXPERIMENTAL VALUES FITTED VALUES
Mesh Opening Mid-Size Feed U'flow O'flow Feed U'flow O'flow

1.05 25400 21997 100.00 100.00 100.00 100.00 100.00 100.00

0.742 19050 15554 100.00 100.00 100.00 100.00 100.00 100.00
0.525 12700 10984 100.00 100.00 100.00 100.00 100.00 100.00
0.371 9500 7978 100.00 100.00 100.00 100.00 100.00 100.00
3 6700 5641 100.00 100.00 100.00 100.00 100.00 100.00
4 4750 3989 100.00 100.00 100.00 100.00 100.00 100.00
6 3350 2812 100.00 100.00 100.00 100.00 100.00 100.00
8 2360 2003 100.00 100.00 100.00 100.00 100.00 100.00
10 1700 1416 100.00 100.00 100.00 100.00 100.00 100.00
14 1180 1001 100.00 100.00 100.00 100.00 100.00 100.00
20 850 714 100.00 100.00 100.00 100.00 100.00 100.00
28 600 505 100.00 100.00 100.00 100.00 100.00 100.00
35 425 357 100.00 100.00 100.00 100.00 100.00 100.00
48 300 252 96.71 95.70 100.00 96.73 95.70 99.99
65 212 178 65.30 54.80 99.30 65.43 54.86 99.10
100 150 126 50.08 35.50 97.30 50.26 35.62 96.92
150 106 89 40.13 23.80 93.00 40.33 23.89 92.70
200 75 63 32.60 16.10 86.00 32.80 16.08 86.06
270 53 45 28.81 12.90 80.30 29.00 12.81 80.60
400 38 19 21.46 7.70 66.00 21.63 7.73 65.91

Ore, ton/hr 131.0 99.5 31.5

Water, m3/hr 102.9 28.1 73.6
Slurry, ton/hr 233.9 127.5 105.1
Slurry, m3/hr 149.7 63.6 84.8
Slurry Dens., ton/m3 1.563 2.006 1.239
% Solids (by volume) 31.25 55.87 13.27
% Solids (by weight) 56.0 78.0 30.0

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Number of Cyclones 1
Classifier Dimensions, inches.
DC h DI DO DU
22 75 3.5 8 3
Classifier Constants
a1 a2 a3 a4 l Cyclone Cyclone Cyclone
13.9665 0.4684307 102.26175 0.0003099 0.2191827 Feed U'flow O'flow
Circulating Load, CL 3.1863696 Solids, tons 131.00 99.71 31.292029
Slurry Split, S 0.7678211 Water, m3/hr 102.13 29.07 73.06
Cyclone Pressure, ft 14.752092 Slurry, tons 233.1292 128.77648 104.35272
Cyclone Pressure, lb/in2 10.00 Slurry, m3/hr 148.91491 64.678495 84.236415
Corrected Cut Size, d50c, microns 45.692882 Solids Density, ton/m3 2.8 2.8 2.8
Water By-Pass 0.2846248 Slurry Density, ton/m3 1.5655195 1.9910246 1.2388077
Fines By-Pass 0.0623848 % Solids (by volume) 31.41775 55.056924 13.267094
Coarse By-Pass 3.727E-05 % Solids (by weight) 56.19 77.43 29.99
Plitt's Parameter 1.1485441
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 0.9999627 0.00 0 0.00 0.00 0.00 0.00
3 12700 15554.26 0.9999627 0.00 0 0.00 0.00 0.00 0.00
4 9500 10984.079 0.9999627 0.00 0 0.00 0.00 0.00 0.00
5 6700 7978.095 0.9999627 0.00 0 0.00 0.00 0.00 0.00
6 4750 5641.3651 0.9999627 0.00 0 0.00 0.00 0.00 0.00
7 3350 3989.0475 0.9999627 0.00 0 0.00 0.00 0.00 0.00
8 2360 2811.761 0.9999627 0.00 0 0.00 0.00 0.00 0.00
9 1700 2002.9978 0.9999627 0.00 0 0.00 0.00 0.00 0.00
10 1180 1416.3333 0.9999627 0.00 0 0.00 0.00 0.00 0.00
11 850 1001.4989 0.9999627 0.00 0 0.00 0.00 0.00 0.00
12 600 714.14284 0.9999627 0.00 0 0.00 0.00 0.00 0.00
13 425 504.97525 0.9999462 0.00 0 0.00 0.00 0.00 0.00
14 300 357.07142 0.9993601 4.29 4.2847624 0.00 3.27 4.30 0.01
15 212 252.1904 0.9931849 41.00 40.720773 0.28 31.30 40.84 0.89
16 150 178.32555 0.9657557 19.87 19.189308 0.68 15.17 19.25 2.17

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17 106 126.0952 0.8985055 13.01 11.690903 1.32 9.93 11.73 4.22

18 75 89.162773 0.7893898 9.87 7.7896714 2.08 7.53 7.81 6.64
19 53 63.047601 0.6560976 4.97 3.2636026 1.71 3.80 3.27 5.47
20 38 44.877611 0.5244078 9.66 5.0654861 4.59 7.37 5.08 14.68
21 0 19 0.2719247 28.33 7.7034638 20.63 21.63 7.73 65.91

Total 131.00 99.71 31.29 100.00 100.00 100.00

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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
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
96.73 95.70 99.99 96.73 95.70 100.00 0.000 0.000 0.000
65.43 54.86 99.10 65.43 54.80 99.30 0.000 0.013 0.041
50.26 35.62 96.92 50.26 35.50 97.30 0.000 0.109 0.149

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40.33 23.89 92.70 40.33 23.80 93.00 0.000 0.149 0.102

32.80 16.08 86.06 32.80 16.10 86.00 0.000 0.016 0.005
29.00 12.81 80.60 29.00 12.90 80.30 0.000 0.527 0.135
21.63 7.73 65.91 21.63 7.70 66.00 0.000 0.114 0.017

Overall
0.049 0.024 0.036

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