Chapter four

Energy balance

4-1 Introduction:

It is not of great concern the precise quantity of energy inherent in the system , but only with
changes occurring in that energy content .
The inherent energy might be :

Potential : Caused by material attraction of component parts of the system .

Kinetic : Arising from the relative motion of the component parts of the system .
Chemical : Associated with those forces binding the atoms together to from molecules
Atomic : The largest reservoir of all , responsible for keeping the complex atomic structure
intact.

The law of conservation of energy states that energy is neither created nor destroyed in any
process . In mathematical form , the statement would read :

input through
system
boundaries

output through
system
boundaries

accumulation
+ within the
system

At steady state :
Accumulation = 0.0
No chemical reaction :
Generation =Consumption = 0.0
Therefore, the mathematical statement becomes:
Heat in =Heat out
4-2 Enthalpy of the ore:
Since there is no heating or cooling to the ore ,the enthalpy of input ore equal the enthalpy of
output ore.
To calculate the enthalpy of ore first we must define the specific heat of it`s content to calculate
the enthalpy , the following table define the basic content of ore and there specific heat and the
fraction of them in the ore

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Chapter four

Energy balance

Table(4-1) : The content of ore and there specific heat and fraction of them in the ore
Content

Specific heat (kJ/kg.K)

Fraction

sio2

-1367.89

0.4

cuo

-12000.78

0.045

caco3

345.78

0.272

Fe

890.46

0.0683

Pd

489.78

0.052

Au

567.78

0.005

Ag

284.5

0.03

Zn

-789.67

0.008

Na2CO3

67.4

0.06

KNO3

-678.04

0.0597

Known that :
H mean = (H,i wt fraction)
Where H,i = cp (T To)
T=25oC.
To= 0oC
By substituting in the above ,enthalpy of ore = -138.164 kJ/kg.
4-3 Enthalpy of the pregnant solution:
By the same way the enthalpy of the pregnant solution can be found, table (4-2) show the
content of the pregnant solution, there specific heat and there fraction in the solution

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Chapter four

Energy balance

Table(4-2): Pregnant solution contents ,there specific heat and there fraction in the solution
Content

Specific heat KJ/Kg.K

Fraction

NaCN

-90.71

0.00005

Water

4.18

0.99985

Gold

567.78

0.000007111

Silver

284.5

0.0000284

By the same way of the ore the enthalpy of the pregnant solution also found which is equal
13.29 KJ/Kg.K.
Then we calculate the energy for our equipment
4-4 Jaw crusher (CR-101):
For the jaw crusher
Power(kw)= m 0.316x wi F (

[1]

m= the flow rate(t/hr).

Wi =work index =12.74.
Dp=80%of feed passing diameter in (mm).
Da=80%of product passing diameter in (mm).
F= crushing factor , which is 0.75 for primary crusher and 1 for the second.
Power=150 0.1316 12.74 0.75 (

= 33.675 kw.

4-5 Agglomerator (V-101):

we can find the power of the drum as following:
HP =
where,
HP = horse power
n = rotational speed, RPM
T = Torque, ft-lbs

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Chapter four

Energy balance

T = Ia
where,
T = Torque, ft-lbf.
I = Moment of Inertia
a = Angular Acceleration, ft/sec2
Then
Moment of Inertia (I) for hollow cylinder = mR2.
I=mR2
m=mass of drum in lb.
R= radius of drum in ft.
the mass and radius of the drum determined in the design chapter
m=10 kg =22.046 lbs.
R=1 m=3.281 ft.
Then I=22.046 x(3.281)2= 237.3011 lb.ft2.
T=Ixa
Also we will give a approximately value because it will determined later in design chapter then
a=29.912 RPM = 29.912 2
= 29.912 2
(3.281)2 =2023.195 ft/sec2.
T=237.30112023.195 = 480106.399 lbf.ft.
HP= nT/5252 =

= 2734.376 hp = 2039.024 KW.

4-5 Vibrating Screen (SC-101):

The following formula can be used in order to to determining power for circular motion
vibrating screens
kW [1]= (mR n 1.25) / (97,400 LRT)
where
kW = design power
mR = total static moment of counterweight assemblies(kg.cm)=0.5x50=25 kg.cm.
n = screen speed (rpm)=50 rpm
1.25 = a reserve factor for cold weather starts, possible unanticipated field machine speed
increases, shortcomings in line voltage, wire sizes etc.
LRT = motor locked rotor torque in a decimal form ie: 250% would be 2.5 in the formula. For
vibrating equipment the general recommendation is that the motor should have a min LRT of
200%
Then ,Power = (25501.25)/(974002) = 0.00821 kw.

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Chapter four

Energy balance

4-6 Cone crusher (CR-102):

Power(kw)= m x 0.316 wi F (

[3]

m= the flow rate(t/hr).

Wi =work index =12.74.
Dp=80%of feed passing diameter in (mm).
Da=80%of product passing diameter in (mm).
F= crushing factor , which is 0.75 for primary crusher and 1 for the second.
Power= 150 0.1316 12.74 (

=44.9 KW

4-7 Pump of the first calibration pond (P-105):

There is a centrifugal pump that used to pump the cyanide solution from the first calibration
pond to the heap it`s power can be calculated as following:
P=q

[3]

Where :
P =power of pump in watt.
=density kg/m3(for solution =1000 kg/m3).
q= flow rate (m3/s)=0.02041 m3/sec.
h= head (m)= 10m( the high of the heap).
g=9.81m/sec2.
P= 1000 x 0.02041 x 9.81x10=2002.221W =2.002221 KW.
The power shaft =
Where: = the efficiency of the motor of pump which taken as 0.6.
Then the power shaft =

= 3.347 KW.

4-8 Pump of the second calibration pond (P-106):

There is a centrifugal pump that used to pump the cyanide solution from the second calibration
pond to the ore before the agglomeration drum it`s power can be calculated as following:

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Chapter four

Energy balance

P=q
Where :
P =power of pump in watt.
=density kg/m3(for solution =1000 kg/m3).
q= flow rate (m3/s)=0.0225 m3/sec.
h= head (m)= 2m( the high of the conveyor belt).
g=9.81m/sec2.
P= 1000 0.0225 9.812 = 4414.5W = 4.4145 KW.
The power shaft =
Where: = the efficiency of the motor of pump which taken as 0.6.
Then the power shaft =

= 7.3575 KW.

4-9 pump of the pressure-leaf filter (P-101):

There is a centrifugal pump that used to pump the pregnant solution from the storage pond to
the leaf-pressure filter, it`s power can be calculated as following:
g
where W = work done( J/kg)
z = difference in elevations (z1 z2) (m)
P = difference in system pressures (P1 P2)(N/m2)
Pf = pressure drop due to friction, including miscellaneous losses,
and equipment losses( N/m2)
p = liquid density(kg/m3)
g = acceleration due to gravity(m/s2).
z = 1.9 m

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Chapter four

Energy balance

P = the pressure inside the filter- the pressure outside the filter
= 700000 101325 =598675 N/m2
Pf

0.

p = 1100 kg/m3
g = 9.81m/s2.
Then w = (9.81 1.9 ) +

= 562.889 J/kg.

The power (P) = W x flow rate of solution

P = 562.889 22.558 = 12697.54061 W = 12.697541 KW
The power shaft =
Where: = the efficiency of the motor of pump which taken as 0.6.
Then the power shaft =

= 21.163 KW.

4-10 Vacuum pump (P-103):

In the dearation tower there is a vacuum pump the power of it can be calculated with the
following equation:
P[3] =
S0=pumping speed of a vacuum pump without counter-pressure, in m3 / s
=the water vapor volume per sec = 0.041 m3/sec.
p= pressure differential between inlet-side connection and pressure-side connection( Pa)
=34663.8 pa
=mechanical efficiency of the pump (approximately 0.85 for vacuum pumps)
P = power requirement or motor rating, in W
P=

= 1672.018588 w = 1.672 KW.

The power shaft =

Where: =0.6.

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Chapter four
Then the power shaft =

Energy balance
=

= 2.7867 KW.

4-11 Agitator of the mixer (V-102):

The shaft power that required by the agitator of the mixer has been found in the chapter of the
Ancillaries Design which is equal 1.2393 KW
4-12 Pump of the filter-press (P-104):
There is a centrifugal pump that used to pump the solution from the mixer to the filter-press,
it`s power can be calculated as following:
g
where W = work done( J/kg)
z = difference in elevations (z1 z2) (m)
P = difference in system pressures (P1 P2)(N/m2)
Pf = pressure drop due to friction, including miscellaneous losses,
and equipment losses( N/m2)
p = liquid density(kg/m3)
g = acceleration due to gravity(m/s2).
z = 1.9 m
P = the pressure inside the filter- the pressure outside the filter
= 80\0000 101325 = 698675 N/m2
Pf

0.

p = 1100 kg/m3
g = 9.81m/s2.
Then w = (9.81

= 653.7981 J/kg.

The power (P) = W x flow rate of solution

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Chapter four

Energy balance

P = 653.7981 x 22.558 = 14748.38 W = 14.74838 KW

The power shaft =
Where: = the efficiency of the motor of pump which taken as 0.6.
Then the power shaft =

= 24.580 KW.

4-13 Pump of recycle of NaCN (P-107):

There is a centrifugal pump that used to pump the cyanide solution from the first calibration
pond to the heap it`s power can be calculated as following:
P=q
Where :
P =power of pump in watt.
=density kg/m3(for solution =1000 kg/m3).
q= flow rate (m3/s)=0.02041 m3/sec.
h= head (m)= 20m( the high of the heap).
g=9.81m/sec2.
P= 1000 x 0.02041 9.8120 = 40044.421W =40.044421 kW
The power shaft =
Where: = the efficiency of the motor of pump which taken as 0.6.
Then the power shaft =

= 66.74007 KW.

4-14 Furnace (F-101):

The gold charge enters the furnace at temperature 25Cand exit at 1200 C, the temperature
1200 C represents the optimum operating temperature for the furnace; operating higher than it
may causes heat losses. The mixture at this temperature is molten.
The required theoretical heat energy Qth consumed during melting is given by:
Qth = Qm + Qsh + Qs + Qen Qex
Where:

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Chapter four

Energy balance

Qm = amount of heat energy to melt the charge material.

Qsh =amount of heat energy to superheat the melt to temperature of superheat.
Qs = heat required to melt slag forming materials.
Qen = energy required for endothermic process.
Qex = amount of heat energy liberated to the surroundings as a result of exothermic reactions.
Theoretically Qen = Qex
Therefore: Qth = Qm + Qsh + Qs
Qm = MCP (1 2) + M H fusion
M = mass of gold charge = 1.55925 T/h
CP = specific heat capacity of the charge material = 1.494 KJ/kg.k
H fusion = latent heat of fusion = 1047.134KJ/kg
1= melting temperature of charge = 1200 C
2= ambient temperature, 25C
Qm = 1.5592510001.494 (1200-25) + 1.5592510001047.134
= 4369968 KJ/h =1213.88 KW
Qsh = MCPsh
sh= amount of superheat temperature, taken as 330 K
Qsh = 1.5592510001.494330 = 768741.44 KJ/h = 213.539 KW
Qs = Ks Gs
Where:
Ks = quantity of slag formed in (kg), taken as 4% of furnace capacity;
Gs = heat energy for slag = 300 kJ/kg.
Qs =0.04 1.559251000300 = 18711KJ/h = 5.198 KW
Qth = Qm + Qsh + Qs = 1213.88+213.539 +5.198 = 1432.617 KW

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Chapter four

Energy balance

4-15 Reference:

[1] http://www.physicsforums.com . (20March 2013,7:50 PM)

[2] http://forum.bulk-online.com. (26March 2013,8:06 PM)
[3]http://www.pfeiffer-vacuum.com . (26 March 2013,8:50 PM)

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