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About the BallBal_Direct Spreadsheet ...
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
12/29/2014 / 6:12 PM
Page 2
12/29/2014 / 6:12 PM
Moly-Cop Tools
TM
(Version 3.0)
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
0.005
Cyclone O'flow
Fresh Feed
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.
12/29/2014 / 6:12 PM
Moly-Cop Tools
TM
(Version 3.0)
BALLBAL : Mass Balance Closure around a Ball Mill Grinding Circuit
Circuit Type
DIRECT
Remarks
Sample N
Balls
Filling,%
38.00
Interstitial
Slurry Filling,%
100.00
Apex
3.67
3.5
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
12/29/2014 / 6:12 PM
Moly-Cop Tools
TM
(Version 3.0)
Sample N
Remarks
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
12/29/2014 / 6:12 PM
Sample:
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
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
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 6
12/29/2014 / 6:12 PM
Sample:
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
Mid-Size
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)
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 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
0.999
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
9.680
a2
1.401
a3
54.950
a4
0.524
l
0.950
Bpc
0.000
12/29/2014 / 6:12 PM
Sample:
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
18.5
22.0
72.0
5.39
38.0
38.0
35.0
Size Distributions
Mill
Mill
Feed
Discharge
Mid-Size
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
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
2.47
Page 8
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
12/29/2014 / 6:12 PM
Number of Cyclones
Classifier Dimensions, inches.
DC
h
DI
DO
20
75
3.5
7.5
Classifier Constants
a1
a2
a3
a4
9.6796047 1.401085 54.94998 0.524202
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
3.669508
l
0.950148
3.057348
1.107862
11.05621
7.98
179.7775
0.391616
0.372093
8.91E-05
1.619455
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
162.28
98.62
260.9006
156.5749
2.8
1.666299
37.01662
62.20
Cyclone
U'flow
122.29
38.62
160.9064
82.2935
2.8
1.955275
53.07084
76.00
Cyclone
O'flow
39.99766
60.00
99.99415
74.28137
2.8
1.346154
19.23077
40.00
ton/hr (model)
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow
Classifier
Efficiency
0.999911
0.999911
0.999911
0.999911
0.999911
0.999911
0.999911
0.999911
0.999911
0.999902
0.998938
0.984245
0.923455
0.810607
0.683104
0.574924
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
Page 9
0
18.17042
41.48635
40.75279
37.00277
38.52856
44.13137
51.20358
66.97024
78.82078
100.4987
120.9252
131.2281
116.4209
85.80095
56.89738
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.11
1.94
10.88
27.20
39.80
42.07
% Retained (model)
Cyclone
Cyclone
Feed
U'flow
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
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
18
19
20
21
75 89.16277
53 63.0476
38 44.87761
0
19
0.497384
0.446966
0.416424
0.383419
Total
Page 10
73.25
53.99
38.98
305.76
36.43228
24.13229
16.23154
117.2336
36.82
29.86
22.75
188.53
4.51
3.33
2.40
18.84
2.98
1.97
1.33
9.59
1622.84
1222.87
399.98
100.00
100.00
(model)
Cyclone
O'flow
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.48
2.72
6.80
9.95
10.52
% Passing (model)
Cyclone
Cyclone
Cyclone
Feed
U'flow
O'flow
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
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
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
% Passing (exp)
Cyclone Cyclone Cyclone
Feed
U'flow
O'flow
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
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
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
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
9.20
7.47
5.69
47.13
24.57
21.24
18.84
12.89
10.91
9.59
60.29
52.82
47.13
24.57
21.24
18.84
12.89
10.91
9.59
60.29
52.82
47.13
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