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Circulating Load Calculations

Screen Efficiency Factors

Circulating Load
- Amount of material deemed
insufficiently processed
Considered for closed-circuit
comminution
Wide particle size distribution

Computed for:
Equipment sizing
Feed control

Problem #1
Given:
100 Mt/h ROM feed
Primary Gyratory Crusher
Product particle size analysis:
70% -
30% +

Single-deck Vibrating Screen


aperture
Screen Efficiency: 100%

1 Pass: t = 1 hour
st

st

70% Undersize
30% Oversize
100% Efficiency

100 Mt

30%

10 GC

70%

Vib
ra t i

70 Mt

ng
Scr
een

30 Mt
+

Re-circulate
to GC!

2 Pass: t = 2 hour
nd

nd

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+30)
=130 Mt

30%

10 GC

70%

Vib
ra t i

70 + (0.7x30)
= 91 Mt

ng
Scr
een

30 + (0.3x30)
= 39 Mt

Re-circulate
to GC!

3 Pass: t = 3 hour
rd

rd

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+39)
=139 Mt
10 GC

Vib
ra t i

70 + (0.7x39)
= 97.30 Mt

ng
Scr
een

30 + (0.3x39)
= 41.70 Mt

Re-circulate
to GC!

4 Pass: t = 4 hour
th

th

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+41.70)
=141.70 Mt

10 GC

Vib
ra t i

70 + (0.7x41.70)
= 99.19 Mt

ng
Scr
een

30 + (0.3x41.70)
= 42.51 Mt

Re-circulate
to GC!

5 Pass: t = 5 hour
th

th

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+42.51)
=142.51 Mt

10 GC

Vib
ra t i

70 + (0.7x42.51)
= 99.76 Mt

ng
Scr
een

30 + (0.3x42.51)
= 42.75 Mt

Re-circulate
to GC!

6 Pass: t = 6 hour
th

th

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+42.75)
=142.75 Mt

10 GC

Vib
ra t i

70 + (0.7x42.75)
= 99.93 Mt

ng
Scr
een

30 + (0.3x42.75)
= 42.83 Mt

Re-circulate
to GC!

7 Pass: t = 7 hour
th

th

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+42.83)
=142.83 Mt

10 GC

Vib
ra t i

70 + (0.7x42.83)
= 99.98 Mt

ng
Scr
een

30 + (0.3x42.83)
= 42.85 Mt

Re-circulate
to GC!

8 Pass: t = 8 hour
th

th

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+42.85)
=142.85 Mt

10 GC

Vib
ra t i

70 + (0.7x42.85)
= 99.99 Mt

ng
Scr
een

30 + (0.3x42.85)
= 42.85 Mt

Re-circulate
to GC!

9 Pass: t = 9 hour
th

th

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+42.85)
=142.85 Mt

10 GC

Vib
ra t i

70 + (0.7x42.85)
= 99.99 Mt

ng
Scr
een

30 + (0.3x42.85)
= 42.86 Mt

Re-circulate
to GC!

10 Pass: t = 10 hour
th

th

New feed:

70% Undersize
30% Oversize
100% Efficiency

(100+42.85)
=142.85 Mt

10 GC

Vib
ra t i

70 + (0.7x42.85)
= 99.99 Mt

ng
Scr
een

30 + (0.3x42.85)
= 42.86 Mt

Re-circulate
to GC!

Total Feed
Total feed is now computed as:
Total Feed Fresh Feed Circulating Load
100 Mt 42.86 Mt
142.86 Mt

Total Feed
May also be computed using the formula:

F
Total Feed
1 - R i
Where:

F
Ri

= Initial Feed
= %Oversize of Crusher Product

Total Feed
Using the formula, total feed may be
computed as:
F
Total Feed
1 - R i
100 Mt 100 Mt

1 0.3 0.7
142.86 Mt

Problem #2
Given:
100 Mt/h ROM feed
Primary Gyratory Crusher
Product particle size analysis:
70% -
30% +

Single-deck Vibrating Screen


aperture
Screen Efficiency: 90%

Take Note:
Screen Efficiency affected by blinding
at lower efficiencies, there are particles,
supposedly undersize, that report to the
oversize fraction!

Formula:

Where:

OSt
%Eff
OSa
%Eff = %Screen Efficiency
OSt = True GC OS fraction
OSa

= Actual Screen OS fraction

Take Note:
To determine the
amount of US that
reported to OS, we use:

OSt
%Eff
OSt x

For the given problem,


we get:

30 Mt
0.90
30 Mt x

30Mt
x
30Mt
0.9
3.33Mt 3.33% of Feed

Now, consider:
70% Undersize
30% Oversize
90% Efficiency

1st Pass 1st hour


100 Mt
10 GC

Vib
ra

(703.33) =
66.67 Mt

ting

S cr
een

(30+3.33) =
33.33 Mt

Re-circulate
to GC!

2 Pass: t = 2 hour
nd

nd

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+33.33)
=133.33 Mt

10 GC

Vib
ra t i

70+(33.33x0.7)
(133.33x0.033)
= 88.89 Mt

ng
Scr
een

Re-circulate
to GC!

30+(33.33x0.3)+(133.33x0.033)
= 44.44 Mt

3 Pass: t = 3 hour
rd

rd

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+44.44)
=144.44 Mt

10 GC

Vib
ra t i

70+(44.44x0.7)
(144.44x0.033)
= 96.30 Mt

ng
Scr
een

Re-circulate
to GC!

30+(44.44x0.3)+(144.44x0.033)
= 48.15 Mt

4 Pass: t = 4 hour
th

th

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+48.15)
=148.15 Mt

10 GC

Vib
ra t i

70+(48.15x0.7)
(148.15x0.033)
= 98.77 Mt

ng
Scr
een

Re-circulate
to GC!

30+(48.15x0.3)+(148.15x0.033)
= 49.38 Mt

5 Pass: t = 5 hour
th

th

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+49.38)
=149.38 Mt

10 GC

Vib
ra t i

70+(49.38x0.7)
(149.38x0.033)
= 99.59 Mt

ng
Scr
een

Re-circulate
to GC!

30+(49.38x0.3)+(149.38x0.033)
= 49.79 Mt

6 Pass: t = 6 hour
th

th

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+49.79)
=149.79 Mt

10 GC

Vib
ra t i

70+(49.79x0.7)
(149.79x0.033)
= 99.86 Mt

ng
Scr
een

Re-circulate
to GC!

30+(49.79x0.3)+(149.79x0.033)
= 49.93 Mt

7 Pass: t = 7 hour
th

th

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+49.93)
=149.93 Mt

10 GC

Vib
ra t i

70+(49.93x0.7)
(149.93x0.033)
= 99.95 Mt

ng
Scr
een

Re-circulate
to GC!

30+(49.93x0.3)+(149.93x0.033)
= 49.98 Mt

8 Pass: t = 8 hour
th

th

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+49.98)
=149.98 Mt

10 GC

Vib
ra t i

70+(49.98x0.7)
(149.98x0.033)
= 99.98 Mt

ng
Scr
een

Re-circulate
to GC!

30+(49.98x0.3)+(149.98x0.033)
= 49.99 Mt

9 Pass: t = 9 hour
th

th

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+49.99)
=149.99 Mt

10 GC

Vib
ra t i

70+(49.99x0.7)
(149.99x0.033)
= 99.99 Mt

ng
Scr
een

Re-circulate
to GC!

30+(49.99x0.3)+(149.99x0.033)
= 50.00 Mt

10 Pass: t = 10 hour
th

th

New feed:

70% Undersize
30% Oversize
90% Efficiency

(100+50.00)
=150.00 Mt

10 GC

Vib
ra t i

70+(50.00x0.7)
(150.00x0.033)
= 100.00 Mt

ng
Scr
een

Re-circulate
to GC!

30+(50.00x0.3)+(150.00x0.033)
= 50.00 Mt

Wait now! Going back


70% Undersize
30% Oversize
90% Efficiency

1st Pass 1st hour


100 Mt
10 GC

Vib
ra

(703.33) =
66.67 Mt

ting

S cr
een

(30+3.33) =
33.33 Mt

Re-circulate
to GC!

Observations:
Based on the 1st Pass, we determine:
33.33% of the Feed reports to Oversize
66.67% of the Feed reports to Undersize

Thus, we can see that:


We use the OS/US cut-off of [33.33% : 66.67%]
66.67%
instead of the original [30% : 70%]
70%
We may perceive the screen efficiency to be
100% again!

1 Pass: t = 1 hour
st

st

66.67% Undersize
33.33% Oversize
100% Efficiency

100 Mt

33.33%

10 GC

66.67%

Vib
ra t i

(703.33) =
66.67 Mt

ng
Scr
een

(30+3.33) =
33.33 Mt

Re-circulate
to GC!

2 Pass: t = 2 hour
nd

nd

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+33.33)
=133.33 Mt

33.33%

10 GC

66.67%

Vib
ra t i

133.33x0.67=
88.89 Mt

ng
Scr
een

133.33x0.33 =
44.44 Mt

Re-circulate
to GC!

3 Pass: t = 3 hour
rd

rd

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+44.44)
=144.44 Mt

10 GC

Vib
ra t i

144.44x0.67=
96.30 Mt

ng
Scr
een

144.44x0.33 =
48.15 Mt

Re-circulate
to GC!

4 Pass: t = 4 hour
th

th

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+48.15)
=148.15 Mt

10 GC

Vib
ra t i

148.15x0.67=
98.77 Mt

ng
Scr
een

148.15x0.33 =
49.38 Mt

Re-circulate
to GC!

5 Pass: t = 5 hour
th

th

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+49.38)
=149.38 Mt

10 GC

Vib
ra t i

149.38x0.67=
99.59 Mt

ng
Scr
een

149.38x0.33 =
49.79 Mt

Re-circulate
to GC!

6 Pass: t = 6 hour
th

th

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+49.79)
=149.79 Mt

10 GC

Vib
ra t i

149.79x0.67=
99.86 Mt

ng
Scr
een

149.79x0.33 =
49.93 Mt

Re-circulate
to GC!

7 Pass: t = 7 hour
th

th

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+49.93)
=149.93 Mt

10 GC

Vib
ra t i

149.93x0.67=
99.95 Mt

ng
Scr
een

149.93x0.33 =
49.98 Mt

Re-circulate
to GC!

8 Pass: t = 8 hour
th

th

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+49.98)
=149.98 Mt

10 GC

Vib
ra t i

149.98x0.67=
99.98 Mt

ng
Scr
een

149.98x0.33 =
49.99 Mt

Re-circulate
to GC!

9 Pass: t = 9 hour
th

th

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+49.99)
=149.99 Mt

10 GC

Vib
ra t i

133.33x0.67=
99.99 Mt

ng
Scr
een

149.99x0.33 =
50.00 Mt

Re-circulate
to GC!

10 Pass: t = 10 hour
th

th

New feed:

66.67% Undersize
33.33% Oversize
100% Efficiency

(100+50.00)
=150.00 Mt

10 GC

Vib
ra t i

150.00x0.67=
100.00 Mt

ng
Scr
een

150.00x0.33 =
50.00 Mt

Re-circulate
to GC!

Total Feed
Total feed is now computed as:
Total Feed Fresh Feed Circulating Load
100 Mt 50 Mt
150 Mt

Total Feed
May also be computed using the formula:

Total Feed

Where:

F
Ri
%Eff
Rj

F
Ri
1% Eff

1 - R j

= Initial Feed
= %Oversize of Crusher Product
= % Screen Efficiency
= Ri / %Eff

Total Feed
Using the formula, total feed may be
computed as:
F
F
Total Feed

1 - R j 1 - R i
%Eff

100 Mt
100 Mt

0 .3
0.67

0 .9

150 Mt

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