INDUSTRIAL

SCREENING
INDUSTRIAL SCREENING 2

 Screening is extensively used for size

separations from 300 mm down to roughly
40 μm, as the efficiency decreases rapidly
with fineness.
 Dry screening is generally limited to material
above ca. 5 mm in size,
 Wet screening down to ca. 250 μm is
common
 Screening is generally limited to material
above 250 µm in size , finer sizing being
undertaken by classification.
 3
The purposes of screening :
1. Sizing or classifying - separate particles by size
2. Scalping - remove the coarsest size fractions in the feed
material
3. Grading: to prepare a number of products within specified
size ranges.
4. Media recovery: for washing magnetic media from ore in
dense medium circuits; or to retain grinding media inside
grinding mills.
5. Dewatering: to drain free moisture from a wet sand slurry.
6. De-sliming or de-dusting: to remove fine material, generally
below 0.5 mm
7. Trash removal: usually to remove coarse wood fibers or
tramp material from a slurry stream
 Performance of Screen
4
- An efficiency equation can be calculated from a mass
balance across a screen.

𝐹 (𝑡/ℎ) = mass flow rate of feed material to the screen.

𝑂 (𝑡/ℎ) = mass flow rate of the coarse product stream
(oversize or overflow stream).
𝑈 (𝑡/ℎ) = mass flow rate of the fine product stream
(undersize or underflow stream).
𝑓 = mass fraction of feed material finer than a defined
cut-point (or cut-size)
𝑜 = mass fraction of material finer than the aperture
size in the coarse product.
𝑢 = mass fraction of material finer than the aperture
size in the fine product.

𝐹 =𝑂+𝑈
 Overall Mass balance around the screen (at steady state)

5
𝐹 =𝑂+𝑈 (1)
 Mass balance of the oversize

𝐹𝑓 = 𝑂𝑜 + 𝑈𝑢 2

 Screen Performance - is defined by the recovery of finished

product (material less than cut-size) to the fine(underflow) stream, 𝐸𝑈
( Colman and Tyler, 1980; Nichols, 1982; Bothwell and Mular, 2002; Valine and Wennen, 2002)

𝑈𝑢 Eq. 3 represents the actual mass of screen

𝐸𝑈 = 𝐹𝑓 (3) undersize that reports to the underflow,
compared to the amount that should
𝑈 𝑓−𝑜 report theoretically, Ff.
= (4) Solving for U/F by rearranging Eq. (1) and
𝐹 𝑢−𝑜 substituting into Eq. (2), the efficiency can
𝑓−𝑜 𝑢 be expressed in terms of the measured
𝐸𝑈 = 𝑢−𝑜 𝑓 (5) undersize mass fractions in each stream
Eq.5
 In most cases (and if there are no broken or deformed apertures), the 6
amount of coarse material in the underflow is usually negligible and a
simplification is to assume u=1(i.e., all particles (100%) reporting to the
fine product stream are below the screen aperture size), in which case
the efficiency reduces to (f, o as fractions):

𝑈 𝑓−𝑜
𝐸𝑈 = = (6)
𝐹𝑓 1−𝑜 𝑓
 If, rather than the fine product, the coarse product is of more interest, a
second definition of efficiency is recovery of oversize to the overflow, 𝐸𝑜 :
𝑂 1−𝑜
𝐸𝑂 = 𝐹 1−𝑓 (7)
➢ or, substituting for O/F in the same way as for U/F
(𝑓 − 𝑢) 1 − 𝑜
𝐸𝑂 = (8)
(𝑜 − 𝑢) 1 − 𝑓
 Efficiency and Circulating Load
Solve for circulating load, R/U

7
 Mass Balances:
Overall: 𝑁 = 𝑈
Around Crusher 𝑂 = 𝑅
Around Screen 𝐹 = 𝑂 + 𝑈
𝐹𝑓 = 𝑂𝑜 + 𝑈𝑢
𝐹𝑓 = 𝑂𝑜 + 𝑈 (assuming u=1; no oversize in the underflow)
𝑈
𝐸𝑈 = 𝐹𝑓

At feed node to screen:

𝑅 1 1
𝐹 =𝑁+𝑅 = 𝑈+𝑅 Then re-arranging = −𝑛
𝑈 𝑟 𝐸𝑈

𝐹𝑓 = 𝑁𝑛 + 𝑅𝑟 = 𝑈𝑛 + 𝑅𝑟
By dividing by U:
𝐹𝑓 𝑅𝑟
=𝑛+
𝑈 𝑈
1 𝑅
Substituting 𝐹𝑓 = 𝑈/𝐸𝑈 = 𝑛 +𝑈𝑟
𝐸
 Efficiency and Circulating Load

𝑅 1 1
8
For (a) C = = −𝑛 (9)
𝑈 𝑟 𝐸𝑈

𝑂 𝐹
For (b) C = 𝑈 = 𝑈 − 1

And from the definition of 𝐸𝑈

we can substitute for F
𝑈
(= 𝐸 𝑓 assuming 𝑢 = 1, then
𝑈

1
C=𝐸 −1 (10)
𝑈𝑓
 9
 Efficiency formulas are acceptable for
assessing the efficiency of a screen under
different working conditions , operating on
the same feed. However , they do not give
an absolute value of the efficiency , if the
feed is composed mainly of particles of a
size near of the screen aperture (near mesh
material ).
 Efficiency or Partition Curve

 For a screen this is drawn by plotting the

partition coefficient, defined as the fraction
(percentage) of the feed reporting to the
oversize product, against the geometric
mean size on a logarithmic scale. (For
particles in the range, say, -8.0 +6.3 mm, the
geometric mean size is 8𝑋6.3 = 57.1 mm. The
Figure shows ideal and real partition curves.
 The separation size, or cut-point, is obtained
at 50% recovery to oversize product, or 50%
probability (i.e., the size of particle which has
equal probability of reporting to the undersize
or oversize product). The cut-point is always
less than the size of the aperture.
 The efficiency of separation is assessed from
the steepness of the partition curve. The
efficiency curve is used for simulation and
design purposes (Napier-Munn et al., 1996;
King, 2012).

10
 Partition coefficient : % of the feed reporting to
the oversize product.
 Geometric mean : e.i. For -125+63 µm particle ,
geometric mean is 125  63
 Cut point : 50 % probability : The size at which
a particle has equal chance of reporting to the
undersize or oversize.
 Cut point size < Aperture size

11
Factors Affecting Screen 12
Performance
The process of screening is frequently described as a series of
probabilistic events, where particles are presented to a
screening surface many times, and on each presentation there
exists a given probability that a particle of a given size will pass.
In its simplest form, the probability of passage for a single
spherical particle size d passing a square aperture with a size x
bordered by a wire diameter w in a single event is given by
Gaudin (1939):

2
𝑥−𝑑
𝑝=
𝑥+𝑤
Particle Size Analysis
Particle Size Analysis

The purpose of size analysis in the lab. :

1. To determine the quality of grinding ,

2. To establish the degree of liberation of valuable
mineral from the gangue at various particle sizes
3. To determine the optimum size of the feed for
maximum efficiency
4. To determine the size range at which any losses are
occuring in the plant

2
Particle Size Analysis

The primary function of precision particle analysis is to

obtain quantitative data about the size and size
distribution of particles in the material
Particle Size and Shape
- For spherical particle : The size is defined by the diameter
- For a cube : Size is defined as the length along one edge
- For irregular particles : Equivalent diameter

3
> Equivalent diameter refers to the diameter of a sphere that
would behave in the same manner as the particle when
submitted to some specified operation.

Several equivalent diameter :

- Stokes’ diameter - measured by sedimentation and elutriation
techniques
- Projected area diameter - measured microscopically
- Sieve aperture diameter – measured by sieving

4
Shape Description Picture

Acicular Needle – shaped

Angular Sharp – edged or having

roughly polyhedral shape

Crystalline Freely developed in a fluid

medium of geometric
shape
Dendritic Having a branched
crystalline shape

Fibrous Plate like

Fibrous

Flaky Plate like

5
Shape Description Picture
Granular : having approximately an
equidimensional irregular
shape
-
Irregular : Lacking any symmetry
-
Modular : Rounded , irregular shape
-
Spherical: Global shape

6
Some Methods of Particle Size Analysis

7
SIEVE ANALYSIS/ TEST SIEVING

Most widely used method of particle size analysis.

Standart test sieving can be accomplished down to
75 m
Particle finer than this size are often referred to as
being Sub Sieve Range , although modern sieving
allows sizing to be carried out down to about 5 m.

8
 Sieving can be carried out in dry and wet condition. Near –Size (near
mesh) materials cause blinding which reduce the effective area of the
sieving medium . It is most serious with very small aperture size.

Sieving takes place into 2- stages:

1. Elimination of particles smaller than the screen apertures (rapid).
2. Separation of the near – size material.
The effectiveness of a sieving test depends on the amount of material
put on the sieve.
9
 TEST SIEVES
Test sieves are designated by the nominal aperture size, which is the
nominal central separation of opposite sides of a square aperture or the
nominal diameter of a round aperture.
◦ German Standard , DIN 4188
◦ ASTM Standard
◦ American Tyler Series
◦ French (AFNOR) Series
◦ British Standard , BS Series

10
 TEST SIEVES
mesh number – refers to the number of wires per inch, which is the
same as the number of square apertures per square inch.

nominal aperture size - is the nominal central separation of opposite

sides of a square aperture or the nominal diameter of a round aperture.

11
Weaves of wire cloth: a.) plain weave b.) twilled weave

12
Important:

In general, the sieve range should be chosen such

that no more than about 5% of the sample is
retained on the coarsest sieve, or passes the finest
sieve.

14
Testing Method

1. Weigh each of the chosen sieves and record (W1).

2. Arrange the chosen sieves in a stack, or nest, with the coarsest sieve on the top and the finest at
the bottom.
3. Place a tight-fitting pan or receiver below the bottom sieve to receive the final undersize.
4. Put a known amount of material on a coarsest screen.
5. Place a lid on top of the coarsest sieve to prevent escape of the sample.
6. Vibrate the nest in a sieve shaker for a determined time.
7. Take apart the nest and weigh the sieve with the material retained and record (W2). The difference
in weight is the weight of your material.
8. Tabulate the results in cum. wt % retained and passing form.

15
Presentation of Results of Sieving Test :

(1) The sieve size ranges used in the test.

(2) The weight of material in each size range.
(3) The weight of material in each size range expressed as a percentage of the total weight.
(4) The nominal aperture sizes of the sieves used in the test.
(5) The cumulative percentage of material passing through the sieves.
(6) The cumulative percentage of material retained on the sieves.
17
 Representation of screen analysis results

Direct plot (Fractional curves )

Reflects the relative frequency of occurrence of the various sizes present
in the material. It shows the mode of the distribution , i.e. the most
commonly occuring size.

18
The Use of Size Analysis in Mass
Balance
In the circuit shown in the Fig, the rod mill is fed at the rate of
20 t/h of dry solids (density 2,900 kg/m3). The cyclone feed
contains 35% solids by weight, and size analyses on the rod mill
discharge and cyclone feed gave:
Rod mill discharge: 26.9% +250um
Ball mill discharge: 4.9% +250um
Cyclone feed: 13.8% +250um
Calculate the volumetric flow rate of feed to the cyclone.

19
The Use of Size Analysis in
Mass Balance
In the circuit shown in the Fig, the rod mill is fed
at the rate of 20 t/h of dry solids (density 2,900
kg/m3). The cyclone feed contains 35% solids by
weight, and size analyses on the rod mill
discharge and cyclone feed gave:
Rod mill discharge : 26.9% +250um
Ball mill discharge : 4.9% +250um
Cyclone feed : 13.8% +250um
Calculate the volumetric flow rate of feed to the
cyclone.

20
 Solution
If we denote

R= mass flow rate of dry solids discharge from Rod Mill

B = mass flow rate of dry solids discharge from the Ball Mill
CF = mass flow rate of dry solids feed to the cyclone

A dry solid material balance on the cyclone feed junction give:

𝐶𝐹 = 𝑅 + 𝐵 𝑜𝑟 𝐶𝐹 = 20 + 𝐵

𝐵 = 𝐶𝐹 − 20

A balance of the +250um material on the cyclone feed junction gives:

𝑥𝐶𝐹 𝐶𝐹 = 𝑥𝑅 𝑅 + 𝑥𝐵 𝐵
13.8𝐶𝐹 = 26.9 20 + 4.9𝐵 𝑜𝑟
49.4𝑡
13.8𝐶𝐹 = 26.9 20 + 4.9 𝐶𝐹 − 20 𝐶𝐹 =
ℎ
21
 Solution

Then,
49.4𝑡 1000𝑘𝑔
𝑚ሶ 𝑋 .
Volumetric flowrate of solids, 𝑉ሶ = = ℎ 𝑡
= 17.0𝑚3 /ℎ
𝐷 2900𝑘𝑔/𝑚3

49.4𝑡 1000𝑘𝑔 65%𝑤𝑎𝑡𝑒𝑟

𝑚ሶ 𝑥 𝑡 𝑥 35%𝑠𝑜𝑙𝑖𝑑𝑠
Volumetric flowrate of water, 𝑉ሶ = =. ℎ
= 91.7𝑚3 /ℎ
𝐷 1000𝑘𝑔/𝑚3

Total Volumetric flowrate of feed in the cyclone =𝑉𝑠ሶ + 𝑉𝑤ሶ = 108.7 m3/h

22
 3 Material Balance,
Metallurgical Accounting
By ABIGAEL L. BALBIN
At the end of this topic, the student
must be able to:
 Analyze process through material balance/ metallurgical accounting
 Determine moisture
 Determine volumetric flowrate
 Determine slurry density
Moisture Determination
 Moisture can be measured automatically. To check, samples for moisture
determination are frequently taken from the end of a conveyor belt after
material has passed over the weighing device. The samples are immediately
weighed wet, dried at a suitable temperature until all hygroscopic (free)
water is driven off, and then weighed again. The difference in weight
represents moisture and is expressed as:

𝑊𝑒𝑡 𝑤𝑒𝑖𝑔ℎ𝑡 − 𝐷𝑟𝑦 𝑊𝑒𝑖𝑔ℎ𝑡

% 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒 = (1)
𝑊𝑒𝑡 𝑊𝑒𝑖𝑔ℎ𝑡

Note: Samples should not be dried at temperatures above 105°C.

Volumetric Flowrate
 For laboratory or small scale operation-> it can be measured by diverting the
stream of pulp into a suitable container for a measured period of time. The
ratio of volume collected to time gives the
 For large scale operation -> flowrate is measured by instrumentation
 Volumetric flowrate is important in calculating retention times in processes

𝑇𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 (𝑚3 ) (2)

𝑅𝑒𝑡𝑒𝑛𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒 =
𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒(𝑚3 /ℎ)
Slurry Density and % Solids
 Slurry, or pulp, density is most easily measured in terms of weight of pulp per
𝑘𝑔 𝑡𝑜𝑛
unit volume (𝑚3 𝑜𝑟 𝑚3 )

 Small flow streams can be diverted into a container of known volume, which
is then weighed to give slurry density directly. This is probably the most
common method for routine assessment of plant performance, and is
facilitated by using a density can of known volume which, when filled, is
weighed on a specially graduated balance giving direct reading of pulp
density.
Note: Refer to laboratory exercises for the detailed procedure
Where 𝑀1 =weight of the density bottle
𝑀2 =weight of the density bottle + sample
𝑀2 − 𝑀1 𝑀3 =weight of the density bottle + sample
𝑠= x 𝐷𝑓 (3)
𝑀4 − 𝑀1 − (𝑀3 − 𝑀2 ) + distilled water
𝑀4 =weight of the density bottle + distilled
water
𝑘𝑔
𝐷𝑓 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 (𝑚3 )
 Slurry Density and % Solids
 Knowing the densities of the pulp and dry solids, the % solids by weight can be
calculated. Since pulp density is mass of slurry divided by volume of slurry,
then for unit mass of slurry of x % solids by weight, the volume of solids is
x/100s and volume of water is (100-x)/100 W then (the 100’s compensating
for x in percent):
𝑚 1
𝑚𝑠 𝑥/100 𝐷= = (4)
𝑉𝑠 = = 𝑉 𝑥 (100 − 𝑥)
+
𝑠 𝑠 100𝑠 100 𝑊
100 − 𝑥
𝑚𝑤 ( )
𝑉𝑤 = = 100 𝑥𝐷 𝐷
𝑊 𝑊 1= + (100 − 𝑥) (5)
100𝑠 100𝑊

Where 𝐷 = pulp density (kg 𝑚−3 )

𝑊 = density of water kg 𝑚−3
s = density of the solids
Slurry Density and % Solids
 Assigning water a density of 1000 kg/𝑚3 , which is sufficiently accurate for
most purposes, gives: 𝑥𝐷 𝐷
1= + (100 − 𝑥)
100𝑠 100(1000)
100𝑠 (𝐷 − 1000) 𝑥𝐷 100 ∗ 1000 + (100 − 𝑥)(𝐷)(100𝑠)
1=
(6) 𝑥 = 100𝑠(100)(1000)
𝐷 (𝑠 − 1000)
100𝑠(100)(1000) = 𝑥𝐷 100 ∗ 1000 + (100 − 𝑥)(𝐷)(100𝑠)

𝑚3
Having measured the slurry volumetric flowrate (F, ℎ
), the pulp density (D,
𝑘𝑔 𝑘𝑔
),and the density of solids (s, 𝑚3), the mass flowrate of slurry can be
𝑚3
calculated (FD, kg/h), and, of more importance, the mass flowrate of dry
solids in the slurry (M, kg/h):

𝑀 = 𝐹𝐷𝑥/100
(7)
Slurry Density and % Solids
 Or combining (6) and (7)

𝐹𝑠 (𝐷 − 1000)
𝑀= (8)
(𝑠 − 1000)

In some cases it is necessary to know the % solids by volume, a parameter, for

example, sometimes used in mathematical models of unit processes:

𝑥𝐷
% solids by volume = (9)
𝑠

Also of use in milling calculations is the ratio of the weight of water to the weight of
solids in the slurry, or the dilution ratio. This is defined as:

100−𝑥
Dilution ratio = (9)
𝑥
Slurry Density and % Solids
Ex. 1 A slurry stream containing quartz is diverted into a 1-liter density can. The
time taken to fill the can is measured as 7 s. The pulp density is measured by
means of a calibrated balance, and is found to be 1400 kg /𝑚3 . Calculate the %
solids by weight, and the mass flowrate of quartz within the slurry.
 The density of the quartz = 2650 kg/𝑚3
Given 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑐𝑎𝑛 = 1
𝑡𝑖𝑚𝑒 𝑡𝑜 𝑓𝑖𝑙𝑙 𝑡ℎ𝑒 𝑐𝑎𝑛 = 7𝑠
D (pulp density) = 1400 km/𝑚3

Using equation 6:

100𝑠 (𝐷 − 1000) 100 ∗ 2650 ∗ (1400 − 1000)

𝑥= = = 45.9%
𝐷 (𝑠 − 1000) 1400(2650 − 1000)

The volumetric flowrate

1𝐿 3600𝑠 1𝑚3
𝐹= ∗ ∗ = 0.51 𝑚3 /ℎ
7𝑠 1ℎ 1000𝐿
Slurry Density and % Solids

The mass flowrate

𝑚3 1400𝑘𝑔 45.9𝑘𝑔 𝑠𝑜𝑙𝑖𝑑𝑠

𝑀 = 0.51 ∗ ∗ = 330.5 𝑘𝑔/ℎ
ℎ 𝑚3 100 𝑘𝑔 𝑠𝑙𝑢𝑟𝑟𝑦
 Ex. 2 A flotation plant treats 500 t of solids per hour. The feed pulp,
containing 40% solids by weight, is conditioned for 5 min with reagents before
being pumped to flotation. Calculate the volume of conditioning tank
required. (Density of solids is 2700 kg/m3).

Given 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 = 500t/h (solids)

𝑥 = 0.40 𝑜𝑟 40%

To solve for the Volume

𝑉𝑇 = 𝑉𝑆 + 𝑉𝑊

500𝑡 1000𝑘𝑔 1ℎ 500𝑡 1000𝑘𝑔 1ℎ

∗ ∗ ∗ ∗
𝑉𝑇 = ℎ 1𝑡 60 𝑚𝑖𝑛 + ℎ 1𝑡 60 𝑚𝑖𝑛 ∗ 100 − 40 ∗ 5 𝑚𝑖𝑛
2700𝑘𝑔 1000𝑘𝑔 40
𝑚3 𝑚3

𝑉 = 77.93 𝑚3
The use of dilution ratios in
Mass Balancing

Water plays a very important role in mineral processing

operations.
> used as a transportation medium for the solids in the
circuit
> also the medium in which most of the mineral separation
takes place.

12
The use of dilution ratios in
Mass Balancing
IF the weight of solids per unit time in the feed, underflow,
and overflow are F, U, and V, respectively
𝐹 =𝑈+𝑉
Dilution ratio of feed slurry
100−𝑓
f’ =
𝑓

Dilution ratio of underflow , Dilution ratio of overflow

100−𝑢 100−𝑣
u’ = v’ =
𝑢 𝑣
Water Balance:
Ff’ = Uu’ + Vv’
13
Ex. 3 A cyclone is fed at the rate of 20t/h of
dry solids. The cyclone feed contains 30%
solids, and the underflow 50% solids, and the
overflow 15% solids by weight. Calculate the
tonnage of solids per hour in the underflow.

14
Solution

Dilution ratio of feed slurry

100−𝑓 (100−30)
f’ = = = 2.33
𝑓 30
Dilution ratio of underflow , Dilution ratio of overflow
100−𝑢 (100−50)
u’ = = 50 = 1.00
𝑢
100−𝑣 (100−15)
v’ = = 15 = 5.67
𝑣
A material balance on the cyclone gives:
20 = U + V
U = 14.3 t/h

15
THANK YOU!
SAMPLING CONTROL AND
MASS BALANCING (PART 2)
By: ABIGAEL L. BALBIN
CONTENT:

 Mass Balancing methods:

> n-product formula
 n-product Formula

 The n-product formula applies to a process unit (or group of process units)
with 1 feed and n products, or n feeds and 1 product, or a total of n+1 feed
and product streams.

 If WF, WC and WT are, respectively, the mass flowrates of feed, concentrate and
tailings, then, assuming steady state, the (solids) mass conservation equation is:

1-Feed A 1-product 𝑊𝐹 = 𝑊𝐶 + 𝑊𝑇 (1)

Tailings

2-product
Concentrate
n-product Formula

 Assuming 𝑥𝐹 , 𝑥𝐶 , and 𝑥 𝑇 are the assay values of the metal of interest, then a
second (or component) mass conservation equation is:

𝑊𝐹 𝑥𝐹 = 𝑊𝐶 𝑥𝐶 + 𝑊𝑇 𝑥𝑇 (2)

 Now, assuming 𝑊𝐹 , 𝑥𝐹 , 𝑥𝐶 , and 𝑥 𝑇 are measured, it follows from the previous 2

equations that:
𝑊𝐹 𝑥𝐶 = 𝑊𝐶 𝑥𝐶 + 𝑊𝑇 𝑥𝐶
𝑊𝐹 𝑥𝐹 = 𝑊𝐶 𝑥𝐶 + 𝑊𝑇 𝑥𝑇
𝑊𝐹 𝑥𝐹 = 𝑊𝐶 𝑥𝐶 + 𝑊𝑇 𝑥𝑇
𝑊𝐹 𝑥𝑇 = 𝑊𝐶 𝑥𝑇 + 𝑊𝑇 𝑥𝑇
𝑊𝐹 (𝑥𝐶 − 𝑥𝐹 ) = 𝑊𝑇 (𝑥𝐶 −𝑥𝑇 )
𝑊𝐹 (𝑥𝐹 − 𝑥𝑇 ) = 𝑊𝐶 (𝑥𝐶 −𝑥𝑇 )
(𝑥 −𝑥 )
(𝑥𝐹 −𝑥𝑇 )
𝑊𝐶 = 𝑊𝐹 (𝑥 −𝑥 ) 𝑊𝑇 = 𝑊𝐹 (𝑥 𝐶−𝑥 𝐹) (3)
𝐶 𝑇
𝐶 𝑇
n-product Formula

 Hence the mass flowrates of concentrate and tailings are both estimable and the
6 values 𝑊𝐹 , 𝑊𝐶 , 𝑊𝑇 , 𝑥𝐹 , 𝑥𝐶 , 𝑥 𝑇 all balanced together

(𝑥𝐶 −𝑥𝐹 )
(𝑥𝐹 −𝑥𝑇 )
𝑊𝐶 = 𝑊𝐹 (𝑥 −𝑥 ) 𝑊𝑇 = 𝑊𝐹 (3)
(𝑥𝐶 −𝑥𝑇 )
𝐶 𝑇

 These equations are known as the 2-product formula

Feed A Tailings

Concentrate
Figure 1. A simple 2-product process unit
 n-product Formula

 From here you can calculate the  And the recovery of metal in your
solid split or yield which is the solid concentrate
in the feed which reports to the
concentrate stream
𝐶𝑐 𝑊𝐶 𝑥𝐶 (3)
(𝑥𝐹 − 𝑥𝑇 ) 𝑅= =
𝐹𝑓 𝑊𝐹 𝑥𝐹
𝑊𝐶 𝑊𝐹 (𝑥𝐶 −𝑥𝑇 )
= (𝑥𝐹 − 𝑥𝑇 )
𝑊𝐹 𝑊𝐹 𝑊𝐹 𝑥
(𝑥𝐶 −𝑥𝑇 ) 𝐶
𝑅=
𝑊𝐶 (𝑥𝐹 − 𝑥𝑇 ) 𝑊𝐹 𝑥𝐹
=
𝑊𝐹 (𝑥𝐶 −𝑥𝑇 ) (𝑥𝐹 − 𝑥𝑇 ) 𝑥𝐶
𝑅= ∗
(𝑥𝐶 −𝑥𝑇 ) 𝑥𝐹
 n-product Formula

 By extension of the 2-product formula, the n-product formula works for a process unit or
group of process units with one feed and n product streams (or any combination of n+1
streams around the process unit). Assuming the mass flowrate of the feed stream is
known, the n-product formula provides a way of calculating the mass flowrates of the n
product streams, provided metal assays are known on each of the n+1 streams. The mass
conservation equations are: (3)
𝑛

𝑊𝐹 = ෍ 𝑊𝑃𝑖
𝑖=1

𝑛
𝐽 𝑗
𝑊𝐹 𝑥𝐹 = ෍ 𝑊𝑃𝑖 𝑥𝑃𝑖
𝑖=1
 n-product Formula

 Ex. The feed to a Zn flotation plant assays 3.93% Zn. The concentrate produced
assays 52.07% Zn and the tailings 0.49% Zn. Calculate the solid split, ratio of
concentration, enrichment ratio, and Zn recovery.
Solution: (3)
Feed A Tailings
𝑋𝑇 = 0.0049
𝑋𝐹 = 0.0393

Concentrate
𝑋𝐶 = 0.5207

𝑊 𝑊
Asked?: 𝑊𝐶 , 𝑊𝐹 , 𝐸. 𝑅. , 𝑅
𝐹 𝐶
 n-product Formula

𝑊𝐶 (𝑥𝐹 −𝑥𝑇 ) 0.0393−0.0049

a.) = = = 0.067 𝑜𝑟 6.7%
𝑊𝐹 (𝑥𝐶 −𝑥𝑇 ) 0.5207−0.0049

𝑊 (𝑥𝐶 −𝑥𝑇 ) 0.5207−0.0049

b.) 𝑊𝐹 = = 0.0393−0.0049 = 15
𝐶 (𝑥𝐹 −𝑥𝑇 )

𝑥𝐶 0.5207
C.) 𝑥 = = 13.25
𝐹 0.0393

(𝑥𝐹 −𝑥𝑇 ) 𝑥𝐶 0.0393−0.0049 0.5207

d.) R = ∗ = ∗ = 0.884 𝑜𝑟 88.4%
(𝑥𝐶 −𝑥𝑇 ) 𝑥𝐹 0.5207−0.0049 0.0393
3-PRODUCTS

 Example: The ore contains galena, sphalerite and gangue. The

amount of feed and assay results are summarized in the table.
Solve for the amount of Pb concentrate, Zinc concentrate,
Recovery of Pb and Zn, Ratio of Concentration of Pb and Zn
PRODUCTS TPD Assays
%Pb %Zn
Feed 600 6.2 8.2
Pb-conc. L 71.8 6.4
Zn-conc. Z 1.4 57.8
Tailing T 0.3 0.8
10
 Solution

 Overall Material Balance Feed A Tailings

𝑊𝐹 = 𝑊𝐿 + 𝑊𝑍 + 𝑊𝑇
Zn Concentrate
600 = 𝑊𝐿 + 𝑊𝑍 + 𝑊𝑇 (1) Pb Concentrate

 Lead Balance
6.2(600) = 71.8𝑊𝐿 + 1.4𝑊𝑍 + 0.3𝑊𝑇 (2)

 Zinc Balance
8.2(600) = 6.4𝑊𝐿 + 57.8𝑊𝑍 + 0.8𝑊𝑇 (3)

11
  L, Z, T are unknowns
 Solution can be found by using
determinant
1 1 1
6.2 1.4 0.3
𝑊𝐿 = 8.2 57.8 0.8
1 1 1 * 600 = 48.36 tons Lead Concentrate
71.8 1.4 0.3
6.4 57.8 0.8

1 1 1
71.8 6.2 0.3
𝑊𝑍 = 6.4 8.2 0.8
1 1 1 * 600 = 73.1 tons Zn Concentrate
71.8 1.4 0.3
6.4 57.8 0.8

𝑊𝑇 = 𝑊𝐹 − 𝑊𝐿 − 𝑊𝑍 = 600 − 48.36 − 73.1 = 478.54 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑡𝑎𝑖𝑙𝑖𝑛𝑔𝑠 12

 𝑊𝐿 𝑥𝐿 48.36(71.8)
𝑅𝐿 = = = 0.933 𝑜𝑟 93.3%
𝑊𝐹 𝑥𝐹𝐿 600(6.2)

𝑊𝑍 𝑥𝑍 73.1(57.8)
𝑅𝑍 = = = 0.859 𝑜𝑟 85.9%
𝑊𝑍 𝑥𝐹𝑍 600(8.2)

𝑊𝐹 600
𝐾𝐿 = = = 12.4
𝑊𝐿 48.36
𝑊𝐹 600
𝐾𝑍 = = = 8.2
𝑊𝑍 73.1

13
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