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BallBal Direct 1
BallBal Direct 1
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 :
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 :
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;
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)
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.
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.
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.
Sample N° 1
100
Weighting Factors :
Streams :
Fresh Feed 0
Mill Discharge 1
Cyclone Feed 1
Cyclone U'flow 1
Cyclone O'flow 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.
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
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
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
CLASSIFIERS PERFORMANCE
Size Distributions
Mill Mill
i Mesh Opening Mid-Size Feed Discharge
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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Overall
0.634 0.184 0.409
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