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Culture Documents
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 ]
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
[(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;
Page 1
4/25/2012 / 9:28 PM
where (% error) corresponds to the combined sampling and measuring error percentage.
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 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 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 pressurised 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 E22 in Control_Panel 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. Eventually, the user may wish to remove the view of the comments by
selecting Tools / Options / View / Comments / None.
Page 2
4/25/2012 / 9:28 PM
Page 3
4/25/2012 / 9:28 PM
Page 4
4/25/2012 / 9:28 PM
Moly-Cop Tools
TM
Weighting Factors :
Streams :
Fresh Feed
Mill Discharge
Cyclone Feed
Cyclone U'flow
Cyclone O'flow
0
1
1
1
1
Size Distributions
% Solids
1
1
Initial Guesses :
Bpf
Bpc
0.372
0.000
d50c
179.8
% Passing
100
10
m
1.619
Mill Discharge
Cyclone U'flow
Obj. Function :
Classifier Constants :
a1
a2
a3
a4
l
0.000
Cyclone O'flow
Fresh Feed
9.68
1.401
54.95
0.524
0.950
10
100
1000
10000
Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
4/25/2012 / 9:28 PM
Moly-Cop Tools
TM
DIRECT
Remarks
Sample N
Balls
Filling,%
38.00
Interstitial
Slurry Filling,%
100.00
Apex
3.67
Lift
Angle, ()
35.0
3348
0
536
3885
10.0
4316
Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW
Charge
Volume,
m3
63.76
psi
7.98
400.0
2.80
7.75
Apparent
Density
ton/m3
5.395
Mesh
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
-400
Opening
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0
Totals
% Solids
Slurry Density, ton/m3
Weighting Factor
Mid-Size
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
ton/hr
0.00
20.00
66.40
56.28
41.32
33.36
27.36
21.64
20.40
15.60
14.16
12.04
10.36
8.84
7.52
6.48
5.52
4.72
3.40
24.60
400.00
Fresh Feed
% Retained % Passing
0.00
5.00
16.60
14.07
10.33
8.34
6.84
5.41
5.10
3.90
3.54
3.01
2.59
2.21
1.88
1.62
1.38
1.18
0.85
6.15
100.00
100.00
100.00
95.00
78.40
64.33
54.00
45.66
38.82
33.41
28.31
24.41
20.87
17.86
15.27
13.06
11.18
9.56
8.18
7.00
6.15
0.00
95.00
2.569
0.000
ton/hr
Mill Discharge
% Retained % Passing
0.00
13.69
31.26
30.71
27.88
29.03
33.26
38.59
50.47
59.40
75.81
92.58
107.08
108.22
94.65
74.57
55.19
40.68
29.37
230.40
1222.84
0.00
1.12
2.56
2.51
2.28
2.37
2.72
3.16
4.13
4.86
6.20
7.57
8.76
8.85
7.74
6.10
4.51
3.33
2.40
18.84
100.00
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
0.00
72.00
1.862
1.000
ton/hr
0.00
18.17
41.49
40.76
37.01
38.53
44.14
51.21
66.98
78.83
100.61
122.86
142.11
143.62
125.60
98.97
73.25
53.99
38.98
305.76
1622.84
Cyclone Feed
% Retained % Passing
0.00
1.12
2.56
2.51
2.28
2.37
2.72
3.16
4.13
4.86
6.20
7.57
8.76
8.85
7.74
6.10
4.51
3.33
2.40
18.84
100.00
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
0.00
62.20
1.666
1.000
ton/hr
Cyclone U'flow
% Retained % Passing
0.00
18.17
41.49
40.76
37.01
38.53
44.14
51.21
66.98
78.83
100.51
120.92
131.20
116.40
85.79
56.90
36.44
24.14
16.23
117.22
1222.84
0.00
1.49
3.39
3.33
3.03
3.15
3.61
4.19
5.48
6.45
8.22
9.89
10.73
9.52
7.02
4.65
2.98
1.97
1.33
9.59
100.00
100.00
100.00
98.51
95.12
91.79
88.76
85.61
82.00
77.81
72.34
65.89
57.67
47.78
37.05
27.54
20.52
15.87
12.89
10.91
9.59
0.00
76.00
1.955
1.000
ton/hr
Cyclone O'flow
% Retained % Passing
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.10
1.94
10.90
27.23
39.81
42.06
36.81
29.86
22.75
188.54
400.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.02
0.49
2.73
6.81
9.95
10.52
9.20
7.46
5.69
47.13
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.97
99.49
96.76
89.96
80.00
69.49
60.29
52.82
47.13
0.00
40.00
1.346
1.000
4/25/2012 / 9:28 PM
Moly-Cop Tools
TM
Remarks
Sample N
psi
7.98
# of Cyclones
Vortex
Apex
10
7.50
3.67
% Solids
76.00
ton/hr
F80
400.0
9795
kWh/ton
Wio
40.00 % Solids
60.29 % - Size 18
150.0 P80
Circ. Load
m3/hr
0.372 Bpf
0.392 Bpw
Water,
m3/hr
10.79
15.08
305.73
1566
Water,
m3/hr
355.1
% Solids
62.20
223.9
Gross kW
% Balls
% Critical
% Solids
4316.1
38.00
72.00
72.00
4/25/2012 / 9:28 PM
Moly-Cop Tools
TM
Sample N
Cyclone
U'flow
1222.9
386.2
1609.2
823.0
1.955
53.1
76.0
Cyclone
O'flow
400.0
600.0
1000.0
742.9
1.346
19.2
40.0
BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks :
Ore, ton/hr
Water, m3/hr
Slurry, ton/hr
Slurry, m3/hr
Slurry Dens., ton/m3
% Solids (by volume)
% Solids (by weight)
Fresh
Feed
400.0
21.1
421.1
163.9
2.569
87.2
95.0
Mill
Mill
Feed
Discharge
1622.9
1622.9
407.3
631.1
2030.2
2254.1
986.9
1210.8
2.057
1.862
58.7
47.9
79.9
72.0
Sump
Water
0.0
355.1
355.1
355.1
1.000
0.0
0.0
Cyclone
Feed
1622.9
986.2
2609.2
1565.8
1.666
37.0
62.2
Mesh
Opening
1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
D80, microns
100.00
100.00
95.00
78.40
64.33
54.00
45.66
38.82
33.41
28.31
24.41
20.87
17.86
15.27
13.06
11.18
9.56
8.18
7.00
6.15
100.00
100.00
97.65
91.00
85.02
80.20
75.77
71.36
66.87
61.49
55.67
48.60
40.41
31.69
23.97
18.22
14.31
11.73
9.95
8.74
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
100.00
100.00
98.51
95.12
91.79
88.76
85.61
82.00
77.82
72.34
65.89
57.68
47.79
37.06
27.54
20.52
15.87
12.89
10.91
9.59
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.99
99.99
99.96
99.48
96.76
89.96
80.01
69.49
60.29
52.82
47.13
9795
4679
1273
1273
2021
150.0
Page 8
4/25/2012 / 9:28 PM
Moly-Cop Tools
TM
Sample N
BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks :
CLASSIFIERS PERFORMANCE
Number of Cyclones :
Cyclone Dimensions, in :
Diameter
Height
Inlet
Vortex
Apex
Ore Density, ton/m3
10
Operating Conditions :
Feed Flowrate, m3/hr
Pressure, psi
D50 (corr.), microns
Water By-Pass, %
Solids By-Pass, %
Plitt's Parameter
Circulating Load, %
20.00
75.00
3.50
7.50
3.67
2.80
1565.8
8.0
179.8
39.2
37.2
1.62
306
i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Mesh
1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
Opening
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
Ore, ton/hr
Water, m3/hr
Slurry, ton/hr
Slurry, m3/hr
Slurry Dens., ton/m3
% Solids (by volume)
% Solids (by weight)
Mid-Size
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
100.00
100.00
98.51
95.12
91.79
88.76
85.61
82.00
77.82
72.34
65.89
57.68
47.79
37.06
27.54
20.52
15.87
12.89
10.91
9.59
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.99
99.99
99.96
99.48
96.76
89.96
80.01
69.49
60.29
52.82
47.13
1622.9
986.2
2609.2
1565.8
1.666
37.0
62.2
1222.9
386.2
1609.2
823.0
1.955
53.1
76.0
400.0
600.0
1000.0
742.9
1.346
19.2
40.0
Page 9
Classifier Efficiency
Actual
Corrected
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.999
0.984
0.923
0.811
0.683
0.575
0.497
0.447
0.416
0.383
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.998
0.975
0.878
0.698
0.495
0.323
0.200
0.119
0.071
0.018
Classifier Constants
a1
a2
a3
a4
l
9.680
1.401
54.950
0.524
0.950
4/25/2012 / 9:28 PM
Moly-Cop Tools
TM
Sample N
BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks :
i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Mesh
1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
Opening
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
18.5
22.0
72.0
5.39
38.0
38.0
35.0
Size Distributions
Mill
Mill
Feed
Discharge
Mid-Size
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
D80, microns
4316
3885
1622.9
79.9
2.66
3.67
Page 10
100.00
100.00
97.65
91.00
85.02
80.20
75.77
71.36
66.87
61.49
55.67
48.60
40.41
31.69
23.97
18.22
14.31
11.73
9.95
8.74
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
4679
1273
4/25/2012 / 9:28 PM
Sample 1
Moly-Cop Tools
TM
DIRECT
Remarks
Balls
Filling,%
38.00
Mesh
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
-400
Opening
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0
Mid-Size
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
Totals
% Solids
Slurry Density, ton/m3
Weighting Factor
ton/hr
0.00
20.00
66.40
56.28
41.32
33.36
27.36
21.64
20.40
15.60
14.16
12.04
10.36
8.84
7.52
6.48
5.52
4.72
3.40
24.60
400.00
Interstitial
Slurry Filling,%
100.00
Apex
3.67
Fresh Feed
% Retained % Passing
0.00
5.00
16.60
14.07
10.33
8.34
6.84
5.41
5.10
3.90
3.54
3.01
2.59
2.21
1.88
1.62
1.38
1.18
0.85
6.15
100.00
100.00
100.00
95.00
78.40
64.33
54.00
45.66
38.82
33.41
28.31
24.41
20.87
17.86
15.27
13.06
11.18
9.56
8.18
7.00
6.15
0.00
95.00
2.569
0.000
Page 11
psi
7.98
Mill Discharge
ton/hr
0.00
13.69
31.26
30.71
27.88
29.03
33.26
38.59
50.47
59.40
75.81
92.58
107.08
108.22
94.65
74.57
55.19
40.68
29.37
230.40
1222.84
Sample 1
Lift
Angle, ()
35.0
3348
0
536
3885
10.0
4316
Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW
Charge
Volume,
m3
63.76
400.0
2.80
7.75
0.00
1.12
2.56
2.51
2.28
2.37
2.72
3.16
4.13
4.86
6.20
7.57
8.76
8.85
7.74
6.10
4.51
3.33
2.40
18.84
100.00
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
0.00
72.00
1.862
1.000
ton/hr
Cyclone Feed
% Retained % Passing
0.00
18.17
41.49
40.76
37.01
38.53
44.14
51.21
66.98
78.83
100.61
122.86
142.11
143.62
125.60
98.97
73.25
53.99
38.98
305.76
1622.84
0.00
1.12
2.56
2.51
2.28
2.37
2.72
3.16
4.13
4.86
6.20
7.57
8.76
8.85
7.74
6.10
4.51
3.33
2.40
18.84
100.00
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
0.00
62.20
1.666
1.000
Page 12
ton/hr
Cyclone U'flow
% Retained % Passing
0.00
18.17
41.49
40.76
37.01
38.53
44.14
51.21
66.98
78.83
100.51
120.92
131.20
116.40
85.79
56.90
36.44
24.14
16.23
117.22
1222.84
0.00
1.49
3.39
3.33
3.03
3.15
3.61
4.19
5.48
6.45
8.22
9.89
10.73
9.52
7.02
4.65
2.98
1.97
1.33
9.59
100.00
100.00
100.00
98.51
95.12
91.79
88.76
85.61
82.00
77.81
72.34
65.89
57.67
47.78
37.05
27.54
20.52
15.87
12.89
10.91
9.59
0.00
76.00
1.955
1.000
Sample 1
Apparent
Density
ton/m3
5.395
ton/hr
Cyclone O'flow
% Retained % Passing
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.10
1.94
10.90
27.23
39.81
42.06
36.81
29.86
22.75
188.54
400.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.02
0.49
2.73
6.81
9.95
10.52
9.20
7.46
5.69
47.13
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.97
99.49
96.76
89.96
80.00
69.49
60.29
52.82
47.13
0.00
40.00
1.346
1.000
Page 13