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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 :

fi = [ 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;

Moly-Cop Tools / 693289493.xlsx Page 1 09/23/2023 / 21:34:49


Moly-Cop Tools / 693289493.xlsx Page 2 09/23/2023 / 21:34:49
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 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, 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 / 693289493.xlsx Page 4 09/23/2023 / 21:34:49
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
Cyclone Feed 1
Cyclone U'flow 1
Cyclone O'flow 1

Size Distributions 1 % Passing 10


% Solids 1

Initial Guesses :
Bpf Bpc d50c m
0.390 0.015 226.8 1.516 4 Mill Discharge
Cyclone U'flow
Obj. Function : 0.640 Cyclone O'flow
Fresh Feed
Classifier Constants :
a1 7.56 1
a2 0.701 10 100 1000 10000
a3 95.21 Particle Size, microns
a4 0.459
l 0.904 Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.

Moly-Cop Tools / 693289493.xlsx 09/23/2023 / 21:34:49


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

Circuit Type DIRECT Sample N° 1

Remarks Base Case Example

Mill Dimensions and Operating Conditions 576 Balls Charge Mill Charge Weight, tons Apparent
Eff. Diam. Eff. Length Speed Charge Balls Interstitial Lift 0 Overfilling Volume, Ball Slurry Density
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, (°) 99 Slurry m3 Charge Interstitial Excess ton/m3
11.5 13.5 75.0 39.00 39.00 100.00 30.0 675 Net Power 15.52 72.62 12.50 0.00 5.485
rpm 16.94 10.0 % Losses
750 Gross kW Feedrate, ton/hr (dry) 78.0
Cyclone Dimensions (inches) and Operating Pressure (psi)
Number Diameter Height Inlet Vortex Apex psi Ore Density, ton/m3 2.80
1 26.0 78.0 6.50 9.00 3.50 6.15 Balls Density, ton/m3 7.80
Default Values: 78.0 6.5 9.1 4.6

EXPERIMENTAL SIZE DISTRIBUTIONS


Fresh Feed Mill Discharge 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 ton/hr % Retained % Passing ton/hr % Retained % Passing

1 1 1/4 " 31750 100.00 100.00 100.00 100.00 100.00


2 1" 25400 28398 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
3 3/4" 19000 21968 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
4 5/8" 16000 17436 0.06 0.08 99.92 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
5 1/2" 12500 14142 0.11 0.14 99.78 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
6 7/16" 11200 11832 1.87 2.40 97.38 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
7 3/8" 9500 10315 3.31 4.24 93.14 2.80 1.54 98.46 4.00 1.54 98.46 1.47 0.81 99.19 0.00 0.00 100.00
8 5/16" 8000 8718 5.19 6.65 86.49 3.14 1.73 96.73 4.49 1.73 96.73 2.00 1.10 98.09 0.00 0.00 100.00
9 1/4" 6300 7099 7.95 10.19 76.30 3.36 1.85 94.88 4.80 1.85 94.88 3.20 1.76 96.33 0.00 0.00 100.00
10 8 2360 3856 23.14 29.67 46.63 8.89 4.89 89.99 12.70 4.89 89.99 12.36 6.80 89.53 0.00 0.00 100.00
11 10 2000 2173 3.21 4.11 42.52 1.67 0.92 89.07 2.39 0.92 89.07 2.74 1.51 88.02 0.00 0.00 100.00
12 20 850 1304 10.69 13.71 28.81 14.10 7.76 81.31 20.15 7.76 81.31 21.37 11.76 76.26 0.05 0.07 99.93
13 40 425 601 5.77 7.40 21.41 28.69 15.79 65.52 41.01 15.79 65.52 39.38 21.67 54.59 1.98 2.54 97.39
14 60 250 326 3.50 4.49 16.92 30.09 16.56 48.96 43.01 16.56 48.96 34.00 18.71 35.88 8.94 11.46 85.93
15 100 150 194 2.78 3.57 13.35 25.17 13.85 35.11 35.97 13.85 35.11 23.88 13.14 22.74 14.22 18.23 67.70
16 140 106 126 1.41 1.81 11.54 11.96 6.58 28.53 17.09 6.58 28.53 10.01 5.51 17.23 7.74 9.92 57.78
17 200 75 89 1.26 1.61 9.93 9.76 5.37 23.16 13.95 5.37 23.16 6.83 3.76 13.47 7.85 10.06 47.72
18 270 53 63 0.97 1.24 8.69 7.00 3.85 19.31 10.00 3.85 19.31 4.29 2.36 11.11 6.02 7.72 40.00
19 325 45 49 0.51 0.66 8.03 3.42 1.88 17.43 4.88 1.88 17.43 1.74 0.96 10.15 2.61 3.34 36.66
20 400 38 41 0.30 0.38 7.65 1.85 1.02 16.41 2.65 1.02 16.41 1.14 0.63 9.52 2.04 2.62 34.04
21 -400 0 19 5.97 7.65 0.00 29.82 16.41 0.00 42.62 16.41 0.00 17.30 9.52 0.00 26.55 34.04 0.00
Totals 78.00 100.00 181.72 100.00 259.72 100.00 181.72 100.00 78.00 100.00

% Solids 98.28 78.30 63.60 76.26 48.40


Slurry Density, ton/m3 2.716 2.014 1.692 1.962 1.452
Weighting Factor 0.000 1.000 1.000 1.000 1.000

Moly-Cop Tools / 693289493.xlsx 09/23/2023 / 21:34:49


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

Remarks Base Case Example

48.25 % Solids
40.10 % - Size 18
psi 6.15 214.2 P80

# of Cyclones 1
Vortex 9.00 Circ. Load 242.85
Apex 3.50 0.390 Bpf m3/hr 243
0.432 Bpw

% Solids 74.87

Water,
m3/hr 73.1
ton/hr 78.0 Water, 9.2
F80 6895 m3/hr

Gross kW 750.0
kWh/ton 9.62 % Balls 39.00
Wio 17.08 % Critical 75.00
% Solids 78.30

% Solids 64.49

Moly-Cop Tools / 693289493.xlsx / Flowsheet 09/23/2023 / 21:34:49


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 78.0 267.4 267.4 0.0 267.4 189.4 78.0
Water, m3/hr 1.4 64.9 74.1 73.1 147.2 63.6 83.7
Slurry, ton/hr 79.4 332.4 341.5 73.1 414.7 253.0 161.7
Slurry, m3/hr 29.2 160.4 169.6 73.1 242.7 131.2 111.5
Slurry Dens., ton/m3 2.716 2.071 2.014 1.000 1.708 1.928 1.450
% Solids (by volume) 95.3 59.5 56.3 0.0 39.3 51.6 25.0
% Solids (by weight) 98.3 80.5 78.3 0.0 64.5 74.9 48.2

Particle Size Distributions (Cummulative % Passing)


i Mesh Opening

11 1/4 " 31750 100.00 100.00 100.00 0.00 100.00 100.00 100.00
2 1" 25400 100.00 100.00 100.00 0.00 100.00 100.00 100.00
3 3/4" 19000 100.00 100.00 100.00 0.00 100.00 100.00 100.00
4 5/8" 16000 99.92 99.98 100.00 0.00 100.00 100.00 100.00
5 1/2" 12500 99.78 99.94 100.00 0.00 100.00 100.00 100.00
6 7/16" 11200 97.38 99.24 100.00 0.00 100.00 100.00 100.00
7 3/8" 9500 93.14 97.09 99.08 0.00 99.08 98.71 99.95
8 5/16" 8000 86.49 94.04 97.95 0.00 97.95 97.15 99.90
9 1/4" 6300 76.30 89.63 96.50 0.00 96.50 95.12 99.82
10 8 2360 46.63 76.24 91.69 0.00 91.69 88.44 99.58
11 10 2000 42.52 74.05 90.68 0.00 90.68 87.04 99.53
12 20 850 28.81 62.10 82.61 0.00 82.61 75.81 99.13
13 40 425 21.41 44.75 66.74 0.00 66.74 54.37 96.78
14 60 250 16.92 30.10 50.20 0.00 50.20 35.53 85.80
15 100 150 13.35 19.86 35.83 0.00 35.83 22.54 68.09
16 140 106 11.54 15.71 29.09 0.00 29.09 17.43 57.40
17 200 75 9.93 12.56 23.54 0.00 23.54 13.65 47.55
18 270 53 8.69 10.45 19.61 0.00 19.61 11.17 40.10
19 325 45 8.03 9.51 17.86 0.00 17.86 10.11 36.68
20 400 38 7.65 8.91 16.71 0.00 16.71 9.43 34.39

D80, microns 6895 3160 766 0 766 1186 214.2

Specific Energy Consumption : 9.62 KWH/ton (Gross)


Operational Work Index : 17.08 KWH/ton

Moly-Cop Tools / 693289493.xlsx Page 8 09/23/2023 / 21:34:49


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

Remarks: Base Case Example

CLASSIFIERS PERFORMANCE

Number of Cyclones : 1 Operating Conditions :


Cyclone Dimensions, in : Feed Flowrate, m3/hr 242.7
Diameter 26.00 Pressure, psi 6.2
Height 78.00 D50 (corr.), microns 226.8
Inlet 6.50 Water By-Pass, % 43.2
Vortex 9.00 Solids By-Pass, % 39.0
Apex 3.50 Plitt's Parameter 1.52
Ore Density, ton/m3 2.80 Circulating Load, % 243

Mass Balance around the Classifiers

Size Distributions, % Passing Classifier Efficiency


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

11 1/4 " 31750 28398 100.00 100.00 100.00 0.985 1.000


2 1" 25400 21968 100.00 100.00 100.00 0.985 1.000
3 3/4" 19000 17436 100.00 100.00 100.00 0.985 1.000
4 5/8" 16000 14142 100.00 100.00 100.00 0.985 1.000
5 1/2" 12500 11832 100.00 100.00 100.00 0.985 1.000
6 7/16" 11200 10315 100.00 100.00 100.00 0.985 1.000
7 3/8" 9500 8718 99.08 98.71 99.95 0.985 1.000
8 5/16" 8000 7099 97.95 97.15 99.90 0.985 1.000
9 1/4" 6300 3856 96.50 95.12 99.82 0.985 1.000
10 8 2360 2173 91.69 88.44 99.58 0.985 1.000
11 10 2000 1304 90.68 87.04 99.53 0.985 1.000
12 20 850 601 82.61 75.81 99.13 0.957 0.952
13 40 425 326 66.74 54.37 96.78 0.806 0.699
14 60 250 194 50.20 35.53 85.80 0.640 0.420
15 100 150 126 35.83 22.54 68.09 0.538 0.248
16 140 106 89 29.09 17.43 57.40 0.482 0.155
17 200 75 63 23.54 13.65 47.55 0.447 0.095
18 270 53 49 19.61 11.17 40.10 0.429 0.065
19 325 45 41 17.86 10.11 36.68 0.421 0.051
20 400 38 19 16.71 9.43 34.39 0.400 0.016

Ore, ton/hr 267.4 189.4 78.0 Classifier Constants


Water, m3/hr 147.2 63.6 83.7 a1 7.562
Slurry, ton/hr 414.7 253.0 161.7 a2 0.701
Slurry, m3/hr 242.7 131.2 111.5 a3 95.214
Slurry Dens., ton/m3 1.708 1.928 1.450 a4 0.459
% Solids (by volume) 39.3 51.6 25.0 l 0.904
% Solids (by weight) 64.5 74.9 48.2 Bpc 0.015

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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 11.5 Mill Power, kW (Gross) 750


Eff. Length, ft 13.5 Mill Power, kW (Net) 675
Speed, % Critical 75.0 Throughput, ton/hr 267.4
App. Density, ton/m3 5.49 % Solids (by weight) 80.5
Charge Level, % 39.0 Sp. Energy, KWH/ton 2.80
Balls Filling, % 39.0 Reduction Ratio 4.13
Lift Angle, (°) 30.0 Arbiter's Flow Number 1.12

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

11 1/4 " 31750 28398 100.00 100.00


2 1" 25400 21968 100.00 100.00
3 3/4" 19000 17436 100.00 100.00
4 5/8" 16000 14142 99.98 100.00
5 1/2" 12500 11832 99.94 100.00
6 7/16" 11200 10315 99.24 100.00
7 3/8" 9500 8718 97.09 99.08
8 5/16" 8000 7099 94.04 97.95
9 1/4" 6300 3856 89.63 96.50
10 8 2360 2173 76.24 91.69
11 10 2000 1304 74.05 90.68
12 20 850 601 62.10 82.61
13 40 425 326 44.75 66.74
14 60 250 194 30.10 50.20
15 100 150 126 19.86 35.83
16 140 106 89 15.71 29.09
17 200 75 63 12.56 23.54
18 270 53 49 10.45 19.61
19 325 45 41 9.51 17.86
20 400 38 19 8.91 16.71

D80, microns 3160 766

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C

Number of Cyclones 1
Classifier Dimensions, inches.
DC h DI DO DU
26 78 6.5 9 3.5
Classifier Constants
a1 a2 a3 a4 l Cyclone Cyclone Cyclone
7.5621653 0.7009005 95.214378 0.4587253 0.9036279 Feed U'flow O'flow
Circulating Load, CL 2.4285045 Solids, tons 259.72 183.97 75.754135
Slurry Split, S 1.1766652 Water, m3/hr 143.00 61.74 81.26
Cyclone Pressure, ft 8.3147333 Slurry, tons 402.72452 245.71319 157.01133
Cyclone Pressure, lb/in2 6.15 Slurry, m3/hr 235.75949 127.44724 108.31224
Corrected Cut Size, d50c, microns 226.76191 Solids Density, ton/m3 2.8 2.8 2.8
Water By-Pass 0.4317724 Slurry Density, ton/m3 1.7082007 1.92796 1.4496176
Fines By-Pass 0.3901616 % Solids (by volume) 39.344483 51.553335 24.978753
Coarse By-Pass 0.0145893 % Solids (by weight) 64.49 74.87 48.25
Plitt's Parameter 1.5160675
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 31750
2 25400 28398.063 0.9854107 0.00 0 0.00 0.00 0.00 0.00
3 19000 21968.159 0.9854107 0.00 0 0.00 0.00 0.00 0.00
4 16000 17435.596 0.9854107 0.00 0 0.00 0.00 0.00 0.00
5 12500 14142.136 0.9854107 0.00 0 0.00 0.00 0.00 0.00
6 11200 11832.16 0.9854107 0.00 0 0.00 0.00 0.00 0.00
7 9500 10315.038 0.9854107 2.40 2.3646115 0.04 0.92 1.29 0.05
8 8000 8717.7979 0.9854107 2.91 2.8717976 0.04 1.12 1.56 0.06
9 6300 7099.2957 0.9854107 3.79 3.7326507 0.06 1.46 2.03 0.07
10 2360 3855.9046 0.9854107 12.48 12.30105 0.18 4.81 6.69 0.24
11 2000 2172.5561 0.9854107 2.61 2.5757665 0.04 1.01 1.40 0.05
12 850 1303.8405 0.9853785 20.96 20.652478 0.31 8.07 11.23 0.40
13 425 601.04076 0.9568696 41.23 39.453735 1.78 15.88 21.45 2.35
14 250 325.96012 0.8063607 42.97 34.645515 8.32 16.54 18.83 10.98
15 150 193.64917 0.6404352 37.32 23.899491 13.42 14.37 12.99 17.71
16 106 126.0952 0.5376239 17.51 9.4127564 8.10 6.74 5.12 10.69

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17 75 89.162773 0.4823764 14.41 6.9514289 7.46 5.55 3.78 9.85


18 53 63.047601 0.4465532 10.20 4.5531313 5.64 3.93 2.47 7.45
19 45 48.836462 0.4290561 4.55 1.9502179 2.60 1.75 1.06 3.43
20 38 41.352146 0.4206122 2.99 1.2578615 1.73 1.15 0.68 2.29
21 0 19 0.3996984 43.40 17.346762 26.05 16.71 9.43 34.39

Total 259.72 183.97 75.75 100.00 100.00 100.00

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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
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
99.08 98.71 99.95 99.08 99.19 100.00 0.000 0.230 0.002
97.95 97.15 99.90 97.95 98.09 100.00 0.000 0.911 0.010
96.50 95.12 99.82 96.50 96.33 100.00 0.000 1.566 0.031
91.69 88.44 99.58 91.69 89.53 100.00 0.000 1.487 0.173
90.68 87.04 99.53 90.68 88.02 100.00 0.000 1.244 0.217
82.61 75.81 99.13 82.61 76.26 99.93 0.000 0.345 0.642
66.74 54.37 96.78 66.74 54.59 97.39 0.000 0.168 0.390
50.20 35.53 85.80 50.20 35.88 85.93 0.000 0.930 0.023
35.83 22.54 68.09 35.83 22.74 67.70 0.000 0.751 0.326
29.09 17.43 57.40 29.09 17.23 57.78 0.000 1.301 0.432

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23.54 13.65 47.55 23.54 13.47 47.72 0.000 1.745 0.122


19.61 11.17 40.10 19.61 11.11 40.00 0.000 0.321 0.068
17.86 10.11 36.68 17.86 10.15 36.66 0.000 0.134 0.003
16.71 9.43 34.39 16.71 9.52 34.04 0.000 0.910 1.065

Overall
0.634 0.184 0.409

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