COMMINUTION EXAMPLE 5303 GRINDING

Grinding

Thefollowingexampledemonstratesasimplegrindingcircuitwithaballmillwitha
re-circulatingload.Fatalerrortroubleshootingwillalsobeaddressed.Ithasbeen
writtenforuserswithMetsimexperience.

AddthefollowingcomponentsusingDBAS:
SOLIDS
AQUEOUS
GAS
SiO2(quartz) H2O
N2
O2
H2O
IntheModelParameters,activatetheHeatBalanceandParticleSizeAnalysis
modules.Changetheunitsofmasstometrictonneandtheunitsoftimetohour.
Whenprompted,selectYestochangetheMeshSieveSeries.SelecttheTYMTyler
SievesandclickOKtouseallofthedefaultscreensizes.FromtheInputmenu,
selectSSNIScreenSieveSeriesforDataEntry.Removeallofthescreenslarger
than1.05inandsmallerthan100TY.
Createtheflowsheetasseenbelow,notingtheorderoftheunitoperations:

Instream1,enter510MT/HRofSiO2.Also,enter1MT/HRofH2Oandenterin0.68
forthe%solids.TheSSAshouldalsobeenteredasseenbelow.

Place1MT/HRofH2Oinstreams20,21,22,and23.
Openthefirstsumpunitoperation(2),settheEngineering
UnitstoEnglish,andselect1-DesignfortheCalculation
Option.Enterinaresidencetimeof5minutes.PlaceaPSC
controlonstream21,checktheboxforON,andenterthe
followingparameters:ID-%SolidstoNo.1Cyclone;OP-2;SN21;PS-0.55;CO-0;CM-0.Calculatethesump.
Openandclosethepump(3)tosetthedefaultparameters
andcalculatethepump.
Openthefirstcycloneunitoperation(4)andchangethe
EngineeringUnitstoEnglish.Settheparametersaslisted:
DC-26;AI-33.8;DV-9;DA-5;HT-78;SL-20;PS-0.7;RP[1]-8;
RP[2]-12.IntheModelParameterstabofthesameunit
operation,select1-KrebsastheCalculationOptionandsetthe
AAparameterto4.Calculatethecyclone.
OpentheballmillandchangetheEngineeringUnitsto
English.Setthefollowingdimensions:CO-BondInside
length;ID-18.5;IL-24.5;CS-0.682;VP-0.45;BD-1.5.Also,set
thefollowingparameters:NF-4;WI-10.9;PF-1;OF-1.2;BE-1.

PlaceaPSConstream22tosetthepercentsolidsintheballmillto68.5%.
Calculatetheballmill.
Openthesecondsump(6)andchangetheEngineeringUnitstoEnglish.Also,set
theCalculationOptiontoDesignandenteraresidencetimeof3minutes.Calculate
thesump.
Openthesecondcycloneunitoperation(7)andchangetheEngineeringUnitsto
English.Setthedimensionsaslisted:DC-26;AI-45;DV-8.5;DA-5;HT-78;SL-20;PS0.7;RP[1]-8;RP[2]-12.TheCalculationOptionshouldbesettoKrebs.
PlaceaPSConstream23withthefollowingparameters:CN-3;OP-6;SN-23;PSVCTL4.PlaceaFBCnearthesecondcycloneunitoperation(7)withthefollowing
parameters:CN-4;OP-7;NO-6;SN-0;LV-0.3;HV-0.7;VF-VP80s9;SP-170;SL-1.
Calculatethesection.
Openandclosetheheader(8)tosetdefaultparametersandcalculatethesection.
Notethatrecyclestream8experiences30iterationsandthenstopsthecalculation
withafatalerror.Tocheckthiserror,gototheModelParameters,Convergencetab,
andchangetheRCYIRecyclestreamiterationlimitfrom30to100.
Recalculatethesection.

SCREEN SIZE ANALYSIS

---------------SCREENS MICRON
---------------.742 IN 18847
.525 IN 13335
.371 IN
9423
3 TY
6730
4 TY
4760
6 TY
3360
8 TY
2380
10 TY
1680
14 TY
1190
20 TY
841
28 TY
595
35 TY
420
48 TY
297
65 TY
210
100 TY
149
150 TY
105
200 TY
74
270 TY
53
400 TY
37
600 TY
26
800 TY
19
1200 TY
13
1600 TY
9
2000 TY
7

STREAM NO. 1
1
P80= 6405
-------------------MT/HR % RET % PAS
-------------------5.100 1.0000 99.00
25.500 5.0000 94.00
30.605 6.0009 88.00
35.695 6.9991 81.00
35.700 7.0000 74.00
35.700 7.0000 67.00
35.700 7.0000 60.00
30.600 6.0000 54.00
35.700 7.0000 47.00
30.600 6.0000 41.00
30.600 6.0000 35.00
35.700 7.0000 28.00
30.600 6.0000 22.00
40.800 8.0000 14.00
30.600 6.0000
8.00
31.209 6.1193
1.88
9.591 1.8807
0.00
0.000 0.0000
0.00
0.000 0.0000
0.00
0.000 0.0000
0.00
0.000 0.0000
0.00
0.000 0.0000
0.00
0.000 0.0000
0.00
0.000 0.0000
0.00

STREAM NO. 6
6
P80= 612
-------------------MT/HR % RET % PAS
-------------------0.00 0.000 100.00
0.18 0.011 99.99
1.26 0.073 99.92
3.16 0.183 99.73
6.11 0.354 99.38
12.41 0.719 98.66
24.44 1.415 97.25
40.39 2.339 94.91
61.73 3.575 91.33
86.69 5.021 86.31
118.39 6.857 79.45
163.55 9.472 69.98
197.16 11.419 58.56
205.15 11.881 46.68
163.15 9.449 37.23
141.74 8.209 29.02
109.15 6.322 22.70
82.51 4.779 17.92
72.63 4.207 13.72
56.81 3.290 10.43
40.16 2.326
8.10
37.77 2.187
5.91
27.47 1.591
4.32
74.61 4.321
0.00

STREAM NO. 7
7
P80= 612
-------------------MT/HR % RET % PAS
-------------------0.00 0.000 100.00
0.18 0.011 99.99
1.26 0.073 99.92
3.16 0.183 99.73
6.11 0.354 99.38
12.41 0.719 98.66
24.44 1.415 97.25
40.39 2.339 94.91
61.73 3.575 91.33
86.69 5.021 86.31
118.39 6.857 79.45
163.55 9.472 69.98
197.16 11.419 58.56
205.15 11.881 46.68
163.15 9.449 37.23
141.74 8.209 29.02
109.15 6.322 22.70
82.51 4.779 17.92
72.63 4.207 13.72
56.81 3.290 10.43
40.16 2.326
8.10
37.77 2.187
5.91
27.47 1.591
4.32
74.61 4.321
0.00

SCREEN SIZE ANALYSIS

---------------SCREENS MICRON
---------------.525 IN 13335
.371 IN
9423
3 TY
6730
4 TY
4760
6 TY
3360
8 TY
2380
10 TY
1680
14 TY
1190
20 TY
841
28 TY
595
35 TY
420
48 TY
297
65 TY
210
100 TY
149
150 TY
105
200 TY
74
270 TY
53
400 TY
37
600 TY
26
800 TY
19
1200 TY
13
1600 TY
9
2000 TY
7

STREAM NO. 8
8
P80= 812
-------------------MT/HR % RET % PAS
-------------------0.18 0.015 99.99
1.26 0.101 99.88
3.16 0.254 99.63
6.11 0.492 99.14
12.41 0.999 98.14
24.44 1.968 96.17
40.39 3.252 92.92
61.73 4.970 87.95
86.69 6.980 80.97
118.38 9.531 71.44
162.94 13.119 58.32
187.50 15.096 43.22
159.94 12.877 30.35
95.86 7.718 22.63
69.23 5.574 17.05
48.76 3.926 13.13
35.37 2.848 10.28
30.47 2.453
7.83
23.54 1.896
5.93
16.53 1.331
4.60
15.48 1.246
3.35
11.22 0.904
2.45
30.43 2.450
0.00

STREAM NO. 9
9
P80= 170
-------------------MT/HR % RET % PAS
-------------------0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.010 0.002 100.00
0.609 0.126 99.87
9.657 1.993 97.88
45.207 9.329 88.55
67.293 13.886 74.66
72.508 14.962 59.70
60.387 12.461 47.24
47.146 9.729 37.51
42.165 8.701 28.81
33.270 6.865 21.95
23.631 4.876 17.07
22.290 4.600 12.47
16.248 3.353
9.12
44.179 9.117
0.00