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.

Moly-Cop Tools / 531091306.xlsx 07/07/2021 / 19:48:29

 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.

Moly-Cop Tools / 531091306.xlsx 07/07/2021 / 19:48:29

Moly-Cop Tools / 531091306.xlsx 07/07/2021 / 19:48:29
 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
0.372 0.000 179.8 1.618 4

Obj. Function : 0.002 Cyclone Feed

Cyclone U'flow
Cyclone O'flow
Classifier Constants : Column E
Column F
a1 9.68 Column G
1
a2 1.401
10 100 1000 10000
a3 54.95
Particle Size, microns
a4 0.523
l 0.950

Moly-Cop Tools / 531091306.xlsx 07/07/2021 / 19:48:29

 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 1622.8
10 20.0 75.0 3.50 7.50 3.67 Volumetric Flow, m3/hr 1565.7
Default Values: 60.0 5.00 7.00 3.75 Cyclones Pressure, psi 7.98

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 18.17 1.12 98.88 18.17 1.49 98.51 0.00 0.00 100.00
4 0.371 9500 10984 41.49 2.56 96.32 41.49 3.39 95.12 0.00 0.00 100.00
5 3 6700 7978 40.76 2.51 93.81 40.76 3.33 91.79 0.00 0.00 100.00
6 4 4750 5641 37.01 2.28 91.53 37.01 3.03 88.76 0.00 0.00 100.00
7 6 3350 3989 38.53 2.37 89.16 38.53 3.15 85.61 0.00 0.00 100.00
8 8 2360 2812 44.14 2.72 86.44 44.14 3.61 82.00 0.00 0.00 100.00
9 10 1700 2003 51.21 3.16 83.28 51.21 4.19 77.81 0.00 0.00 100.00
10 14 1180 1416 66.98 4.13 79.16 66.98 5.48 72.34 0.00 0.00 100.00
11 20 850 1001 78.83 4.86 74.30 78.83 6.45 65.89 0.00 0.00 100.00
12 28 600 714 100.61 6.20 68.10 100.51 8.22 57.67 0.10 0.02 99.97
13 35 425 505 122.86 7.57 60.53 120.92 9.89 47.78 1.94 0.49 99.49
14 48 300 357 142.11 8.76 51.77 131.20 10.73 37.05 10.90 2.73 96.76
15 65 212 252 143.62 8.85 42.92 116.40 9.52 27.54 27.23 6.81 89.96
16 100 150 178 125.60 7.74 35.18 85.79 7.02 20.52 39.81 9.95 80.00
17 150 106 126 98.97 6.10 29.08 56.90 4.65 15.87 42.06 10.52 69.49
18 200 75 89 73.25 4.51 24.57 36.44 2.98 12.89 36.81 9.20 60.29
19 270 53 63 53.99 3.33 21.24 24.14 1.97 10.91 29.86 7.46 52.82
20 400 38 45 38.98 2.40 18.84 16.23 1.33 9.59 22.75 5.69 47.13
21 -400 0 19 305.76 18.84 0.00 117.22 9.59 0.00 188.54 47.13 0.00
Totals 1622.84 100.00 1222.84 100.00 400.00 100.00

% Solids 62.20 76.00 40.00

Weighting Factor 1.000 1.000 1.000

Moly-Cop Tools / 531091306.xlsx 07/07/2021 / 19:48:29

 Moly-Cop Tools TM
(Version 3.0)

CYCLOBAL Sample N° 1
Cyclone Mass Balance Closure

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 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 98.88 98.51 100.00 1.000 1.000
0.371 9500 7978 96.32 95.12 100.00 1.000 1.000
3 6700 5641 93.81 91.79 100.00 1.000 1.000
4 4750 3989 91.53 88.76 100.00 1.000 1.000
6 3350 2812 89.16 85.61 100.00 1.000 1.000
8 2360 2003 86.44 82.00 100.00 1.000 1.000
10 1700 1416 83.28 77.81 100.00 1.000 1.000
14 1180 1001 79.16 72.34 100.00 1.000 1.000
20 850 714 74.30 65.89 100.00 0.999 0.998
28 600 505 68.10 57.67 99.97 0.984 0.975
35 425 357 60.53 47.78 99.49 0.923 0.878
48 300 252 51.77 37.05 96.76 0.811 0.698
65 212 178 42.92 27.54 89.96 0.683 0.495
100 150 126 35.18 20.52 80.01 0.575 0.323
150 106 89 29.08 15.87 69.49 0.497 0.200
200 75 63 24.57 12.89 60.29 0.447 0.119
270 53 45 21.24 10.91 52.82 0.416 0.071
400 38 19 18.84 9.59 47.14 0.383 0.018

D80, microns 1273 2022 150.0

Ore, ton/hr 1622.8 1222.9 400.0 Classifier Constants

Water, m3/hr 986.2 386.2 600.0 a1 9.680
Slurry, ton/hr 2609.0 1609.0 1000.0 a2 1.401
Slurry, m3/hr 1565.7 822.9 742.8 a3 54.946
Slurry Dens., ton/m3 1.666 1.955 1.346 a4 0.523
% Solids (by volume) 37.0 53.1 19.2 l 0.950
% Solids (by weight) 62.2 76.0 40.0 Bpc 0.000

Moly-Cop Tools / 531091306.xlsx Page 6 07/07/2021 / 19:48:29

 Moly-Cop Tools TM
(Version 3.0)

CYCLOBAL Sample N° 1
Raw Experimental Data

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
Inlet 3.50
Vortex 7.50
Apex 3.67
Ore Density, ton/m3 2.80 Circulating Load, % 306

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 98.88 98.51 100.00 98.88 98.51 100.00
0.371 9500 7978 96.32 95.12 100.00 96.32 95.12 100.00
3 6700 5641 93.81 91.79 100.00 93.81 91.79 100.00
4 4750 3989 91.53 88.76 100.00 91.53 88.76 100.00
6 3350 2812 89.16 85.61 100.00 89.16 85.61 100.00
8 2360 2003 86.44 82.00 100.00 86.44 82.00 100.00
10 1700 1416 83.28 77.81 100.00 83.28 77.81 100.00
14 1180 1001 79.16 72.34 100.00 79.16 72.34 100.00
20 850 714 74.30 65.89 100.00 74.30 65.89 100.00
28 600 505 68.10 57.67 99.97 68.10 57.67 99.97
35 425 357 60.53 47.78 99.49 60.53 47.78 99.49
48 300 252 51.77 37.05 96.76 51.77 37.05 96.76
65 212 178 42.92 27.54 89.96 42.92 27.54 89.96
100 150 126 35.18 20.52 80.00 35.18 20.52 80.01
150 106 89 29.08 15.87 69.49 29.08 15.87 69.49
200 75 63 24.57 12.89 60.29 24.57 12.89 60.29
270 53 45 21.24 10.91 52.82 21.24 10.91 52.82
400 38 19 18.84 9.59 47.13 18.84 9.59 47.14

Ore, ton/hr 1622.8 1222.8 400.0

Water, m3/hr 986.2 386.2 600.0
Slurry, ton/hr 2609.0 1609.0 1000.0
Slurry, m3/hr 1565.7 822.9 742.9
Slurry Dens., ton/m3 1.666 1.955 1.346
% Solids (by volume) 37.02 53.07 19.23
% Solids (by weight) 62.2 76.0 40.0

Moly-Cop Tools / 531091306.xlsx Page 7 07/07/2021 / 19:48:29

 C

Number of Cyclones 10
Classifier Dimensions, inches.
DC h DI DO DU
20 75 3.5 7.5 3.669508
Classifier Constants
a1 a2 a3 a4 l Cyclone Cyclone Cyclone
9.6796053 1.401158 54.94554 0.523394 0.950027 Feed U'flow O'flow
Circulating Load, CL 3.057176 Solids, tons 162.28 122.29 39.99936
Slurry Split, S 1.107773 Water, m3/hr 98.62 38.62 60.00
Cyclone Pressure, ft 11.05621 Slurry, tons 260.9006 160.9022 99.99839
Cyclone Pressure, lb/in2 7.98 Slurry, m3/hr 156.5749 82.29035 74.28452
Corrected Cut Size, d50c, microns 179.7869 Solids Density, ton/m3 2.8 2.8 2.8
Water By-Pass 0.39159 Slurry Density, ton/m3 1.666299 1.955298 1.346154
Fines By-Pass 0.372021 % Solids (by volume) 37.01662 53.07213 19.23077
Coarse By-Pass 3.75E-05 % Solids (by weight) 62.20 76.00 40.00
Plitt's Parameter 1.618198
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 21997.05 0.999963 0.00 0 0.00 0.00 0.00 0.00
3 12700 15554.26 0.999963 18.17 18.17136 0.00 1.12 1.49 0.00
4 9500 10984.08 0.999963 41.49 41.48849 0.00 2.56 3.39 0.00
5 6700 7978.095 0.999963 40.76 40.7549 0.00 2.51 3.33 0.00
6 4750 5641.365 0.999963 37.01 37.00468 0.00 2.28 3.03 0.00
7 3350 3989.048 0.999963 38.53 38.53055 0.00 2.37 3.15 0.00
8 2360 2811.761 0.999963 44.14 44.13365 0.00 2.72 3.61 0.00
9 1700 2002.998 0.999963 51.21 51.20622 0.00 3.16 4.19 0.00
10 1180 1416.333 0.999963 66.98 66.97369 0.00 4.13 5.48 0.00
11 850 1001.499 0.999954 78.83 78.82483 0.00 4.86 6.45 0.00
12 600 714.1428 0.998978 100.61 100.5028 0.10 6.20 8.22 0.03
13 425 504.9752 0.984213 122.86 120.9213 1.94 7.57 9.89 0.48
14 300 357.0714 0.923339 142.11 131.2116 10.89 8.76 10.73 2.72
15 212 252.1904 0.810506 143.62 116.4063 27.22 8.85 9.52 6.80
16 150 178.3255 0.683078 125.60 85.79757 39.81 7.74 7.02 9.95

Page 8
 C

17 106 126.0952 0.574952 98.97 56.90014 42.06 6.10 4.65 10.52

18 75 89.16277 0.497426 73.25 36.43535 36.81 4.51 2.98 9.20
19 53 63.0476 0.446995 53.99 24.13387 29.86 3.33 1.97 7.46
20 38 44.87761 0.416432 38.98 16.23184 22.75 2.40 1.33 5.69
21 0 19 0.38338 305.76 117.2217 188.54 18.84 9.59 47.14

Total 1622.84 1222.85 399.99 100.00 100.00 100.00

Page 9
 C

% 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 77.81 100.00 83.28 77.81 100.00 0.000 0.000 0.000
79.16 72.34 100.00 79.16 72.34 100.00 0.000 0.000 0.000
74.30 65.89 100.00 74.30 65.89 100.00 0.000 0.000 0.000
68.10 57.67 99.97 68.10 57.67 99.97 0.000 0.000 0.000
60.53 47.78 99.49 60.53 47.78 99.49 0.000 0.000 0.000
51.77 37.05 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

Page 10
 C

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 47.14 18.84 9.59 47.13 0.000 0.000 0.000

Overall
0.000 0.000 0.000

Page 11