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About the BallBal_Reverse Spreadsheet ...
Scope :
The BallBal_Reverse 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 Reverse 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 circuit, for particles
of size di :
fiF F + fiMD MD = fiU U + fiO O
???
, for i = 1,n
will never be satisfied. In the above expression F, MD, U and O represent the mass flowrate of solids in the circuit fresh
feed, mill discharge, underflow and overflow streams, respectively. Similarly, fiF, fiMD, fiU and fiO represent the fraction of
those total respective streams corresponding to particles of size d i.
The Ballbal_Reverse routine allows for the calculation of a whole new set of corresponding adjusted or fitted values fiF,
fiMD, fiU and fiO, such that the objective functions :
fi = [ wF (fiF - fiF)2 + wMD (fiMD - fiMD)2 + wU (fiU - fiU)2 + wO(fiO - fiO)2 ]
are minimized and the adjusted values so generated strictly satisfy the mass balance restrictions :
fiF F + fiMD MD = fiU U + fiO O
, for i = 1,n
where wF, wMD, wU and wO are user defined weighting factors included to represent the relative quality and reliability of the
samples from each of the 4 streams and the mass flowrates F, MD, U and O are calculated as :
F =
MD =
U =
O =
F
F (CL)
F (CL)
F
[(fiO - fiF) / (fiMD - fiU)] + ufs (1/fSO - 1/fSF) / (1/fSMD -1/fSU) } / (usd + ufs)
all i
where fsF, fsMD, fsU and fsO are the weight fractions of total solids in the fresh feed, mill discharge, 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 4 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.
Page 1
5/5/2014 / 1:37 PM
Page 2
5/5/2014 / 1:37 PM
TM
Moly-Cop Tools
(Version 2.0)
Weighting Factors
Streams :
Fresh Feed
Mill Discharge
Cyclone Feed
Cyclone U'flow
Cyclone O'flow
0
1
1
1
1
Size Distr.
% Solids
1
1
Initial Guesses :
Bpf
Bpc
0.425
0.000
Obj. Function :
d50c
194.4
% Passing
100
10
m
1.451
Mill Discharge
Cyclone U'flow
0.003
Cyclone O'flow
Fresh Feed
Classifier Constants :
a1
a2
a3
a4
l
9.68
1.401
54.95
0.524
0.950
1
10
100
1000
10000
Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
5/5/2014 / 1:37 PM
Moly-Cop Tools
TM
(Version 2.0)
BALLBAL : Mass Balance Closure around a Ball Mill Grinding Circuit
Circuit Type
REVERSE
Sample N
Remarks
Balls
Filling,%
38.00
Interstitial
Slurry Filling,%
100.00
Apex
4.05
3.5
Lift
Angle, ()
35.0
3348
0
536
3884
10.0
4316
Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW
Charge
Volume,
m3
63.76
psi
9.41
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
Mid-Size
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
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
17.19
39.23
38.54
35.00
36.46
41.78
48.49
63.45
74.69
95.00
114.06
128.50
128.56
114.27
92.85
70.83
53.26
39.03
308.62
1539.79
0.00
1.12
2.55
2.50
2.27
2.37
2.71
3.15
4.12
4.85
6.17
7.41
8.35
8.35
7.42
6.03
4.60
3.46
2.53
20.04
100.00
100.00
100.00
98.88
96.34
93.83
91.56
89.19
86.48
83.33
79.21
74.36
68.19
60.78
52.44
44.09
36.67
30.64
26.04
22.58
20.04
0.00
72.00
1.862
1.000
ton/hr
0.00
37.19
105.63
94.82
76.32
69.82
69.14
70.13
83.85
90.29
109.16
126.10
138.86
137.40
121.79
99.33
76.35
57.98
42.43
333.22
1939.79
Cyclone Feed
% Retained % Passing
0.00
1.92
5.45
4.89
3.93
3.60
3.56
3.62
4.32
4.65
5.63
6.50
7.16
7.08
6.28
5.12
3.94
2.99
2.19
17.18
100.00
100.00
100.00
98.08
92.64
87.75
83.81
80.22
76.65
73.04
68.71
64.06
58.43
51.93
44.77
37.69
31.41
26.29
22.35
19.37
17.18
0.00
64.10
1.701
1.000
ton/hr
Cyclone U'flow
% Retained % Passing
0.00
37.19
105.63
94.82
76.32
69.82
69.14
70.13
83.85
90.26
108.52
121.55
123.90
108.66
83.81
59.89
41.27
28.87
19.98
146.20
1539.79
0.00
2.42
6.86
6.16
4.96
4.53
4.49
4.55
5.45
5.86
7.05
7.89
8.05
7.06
5.44
3.89
2.68
1.88
1.30
9.49
100.00
100.00
100.00
97.58
90.72
84.57
79.61
75.08
70.59
66.03
60.59
54.72
47.68
39.78
31.74
24.68
19.24
15.35
12.67
10.79
9.49
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
0.03
0.65
4.55
14.96
28.74
37.98
39.44
35.09
29.10
22.45
187.02
400.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.16
1.14
3.74
7.18
9.49
9.86
8.77
7.28
5.61
46.75
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.83
98.69
94.95
87.77
78.27
68.41
59.64
52.37
46.75
0.00
40.00
1.346
1.000
5/5/2014 / 1:37 PM
Moly-Cop Tools
TM
(Version 2.0)
Sample N
Remarks
40.00 % Solids
59.64 % - Size 18
160.2 P80
9.41 psi
Bpf
Bpw
ton/hr
F80
Water,
m3/hr
400.0
9795
10 # of Cyclones
7.50 Vortex
4.05 Apex
76.00 % Solids
3
112.6 Water, m /hr
466.4
Gross kW
% Balls
% Critical
% Solids
kWh/ton
Wio
0.425
0.448
4316.0
38.00
72.00
72.00
Circ. Load
m3/hr
% Solids
384.94
1779
64.10
10.79
15.66
5/5/2014 / 1:37 PM
Sample N
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
1539.8
1539.8
486.2
598.8
2026.0
2138.6
1036.2
1148.7
1.955
1.862
53.1
47.9
76.0
72.0
Sump
Water
0.0
466.4
466.4
466.4
1.000
0.0
0.0
Cyclone
Feed
1939.8
1086.2
3026.0
1779.0
1.701
38.9
64.1
Cyclone
U'flow
1539.8
486.2
2026.0
1036.2
1.955
53.1
76.0
Cyclone
O'flow
400.0
600.0
1000.0
742.9
1.346
19.2
40.0
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
97.58
90.73
84.57
79.61
75.08
70.59
66.03
60.59
54.73
47.68
39.78
31.74
24.68
19.24
15.35
12.67
10.79
9.49
100.00
100.00
98.88
96.34
93.83
91.56
89.19
86.48
83.33
79.21
74.36
68.19
60.78
52.44
44.09
36.67
30.64
26.04
22.58
20.04
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
98.08
92.64
87.75
83.81
80.22
76.65
73.04
68.71
64.06
58.43
51.93
44.77
37.69
31.41
26.29
22.35
19.37
17.18
100.00
100.00
97.58
90.73
84.57
79.61
75.08
70.59
66.03
60.59
54.73
47.68
39.78
31.74
24.68
19.24
15.35
12.67
10.79
9.49
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.99
99.99
99.82
98.69
94.95
87.77
78.27
68.41
59.64
52.37
46.75
9795
4884
1267
3281
4884
160.2
Page 6
5/5/2014 / 1:37 PM
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
4.05
2.80
1779.0
9.4
194.4
44.8
42.5
1.45
385
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
97.58
90.73
84.57
79.61
75.08
70.59
66.03
60.59
54.73
47.68
39.78
31.74
24.68
19.24
15.35
12.67
10.79
9.49
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.99
99.99
99.82
98.69
94.95
87.77
78.27
68.41
59.64
52.37
46.75
1939.8
1086.2
3026.0
1779.0
1.701
38.9
64.1
1539.8
486.2
2026.0
1036.2
1.955
53.1
76.0
400.0
600.0
1000.0
742.9
1.346
19.2
40.0
Page 7
Classifier Efficiency
Actual
Corrected
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.994
0.964
0.892
0.791
0.688
0.603
0.540
0.498
0.471
0.439
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.999
0.990
0.937
0.813
0.636
0.457
0.309
0.200
0.126
0.079
0.023
Classifier Constants
a1
9.679
a2
1.401
a3
54.945
a4
0.524
l
0.950
Bpc
0.000
5/5/2014 / 1:37 PM
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
3884
1539.8
76.0
2.80
3.85
2.34
Page 8
100.00
100.00
97.58
90.73
84.57
79.61
75.08
70.59
66.03
60.59
54.73
47.68
39.78
31.74
24.68
19.24
15.35
12.67
10.79
9.49
100.00
100.00
98.88
96.34
93.83
91.56
89.19
86.48
83.33
79.21
74.36
68.19
60.78
52.44
44.09
36.67
30.64
26.04
22.58
20.04
4884
1267
5/5/2014 / 1:37 PM
Number of Cyclones
Classifier Dimensions, inches.
DC
h
DI
DO
20
75
3.5
7.5
Classifier Constants
a1
a2
a3
a4
9.6794805 1.401179 54.94513 0.523572
Circulating Load, CL
Slurry Split, S
Cyclone Pressure, ft
Cyclone Pressure, lb/in2
Corrected Cut Size, d50c, microns
Water By-Pass
Fines By-Pass
Coarse By-Pass
Plitt's Parameter
Opening
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
Mid-Size
21997.05
15554.26
10984.08
7978.095
5641.365
3989.048
2811.761
2002.998
1416.333
1001.499
714.1428
504.9752
357.0714
252.1904
178.3255
126.0952
10
DU
4.054711
l
0.950075
3.849413
1.394819
12.77407
9.41
194.3752
0.447633
0.425285
4.05E-05
1.451339
Solids, tons
Water, m3/hr
Slurry, tons
Slurry, m3/hr
Solids Density, ton/m3
Slurry Density, ton/m3
% Solids (by volume)
% Solids (by weight)
Cyclone
Feed
193.98
108.63
302.6044
177.9034
2.8
1.700948
38.94155
64.10
Cyclone
U'flow
153.98
48.62
202.6029
103.6166
2.8
1.955314
53.07297
76.00
Cyclone
O'flow
40.00057
60.00
100.0014
74.28678
2.8
1.346154
19.23077
40.00
ton/hr (model)
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow
Classifier
Efficiency
0.99996
0.99996
0.99996
0.99996
0.99996
0.99996
0.99996
0.99996
0.999957
0.999636
0.994071
0.963954
0.892334
0.790915
0.688185
0.602932
0.00
37.19
105.63
94.82
76.32
69.82
69.14
70.13
83.85
90.29
109.16
126.10
138.86
137.40
121.79
99.33
Page 9
0
37.19084
105.6231
94.81705
76.32015
69.81478
69.13236
70.12745
83.8422
90.25515
108.5168
121.555
123.9085
108.6727
83.81329
59.88834
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.65
4.55
14.95
28.73
37.98
39.44
% Retained (model)
Cyclone
Cyclone
Feed
U'flow
0.00
1.92
5.45
4.89
3.93
3.60
3.56
3.62
4.32
4.65
5.63
6.50
7.16
7.08
6.28
5.12
0.00
2.42
6.86
6.16
4.96
4.53
4.49
4.55
5.45
5.86
7.05
7.89
8.05
7.06
5.44
3.89
18
19
20
21
75 89.16277
53 63.0476
38 44.87761
0
19
0.540441
0.497972
0.470827
0.438754
76.35 41.26454
57.98 28.8701
42.43 19.97567
333.22 146.1994
Total
Page 10
1939.79
1539.79
35.09
29.11
22.45
187.02
3.94
2.99
2.19
17.18
2.68
1.87
1.30
9.49
400.01
100.00
100.00
(model)
Cyclone
O'flow
% Passing (model)
Cyclone
Cyclone
Cyclone
Feed
U'flow
O'flow
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.16
1.14
3.74
7.18
9.49
9.86
100.00
100.00
98.08
92.64
87.75
83.81
80.22
76.65
73.04
68.71
64.06
58.43
51.93
44.77
37.69
31.41
26.29
100.00
100.00
97.58
90.73
84.57
79.61
75.08
70.59
66.03
60.59
54.73
47.68
39.78
31.74
24.68
19.24
15.35
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.99
99.99
99.82
98.69
94.95
87.77
78.27
68.41
% Passing (exp)
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow
100.00
100.00
98.08
92.64
87.75
83.81
80.22
76.65
73.04
68.71
64.06
58.43
51.93
44.77
37.69
31.41
26.29
100.00
100.00
97.58
90.72
84.57
79.61
75.08
70.59
66.03
60.59
54.72
47.68
39.78
31.74
24.68
19.24
15.35
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.83
98.69
94.95
87.77
78.27
68.41
Page 11
(Weighted Error)^2
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow
1
1
1
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
8.77
7.28
5.61
46.75
22.35
19.37
17.18
12.67
10.79
9.49
59.64
52.37
46.75
22.35
19.37
17.18
12.67
10.79
9.49
59.64
52.37
46.75
100.00
Page 12
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Overall
0.000