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 :
i = [ wCF (fiCF - fiCF)2 + wU (fiU - fiU)2 + wO(fiO - fiO)2 ]

,for every particle size di

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;

Moly-Cop Tools / 288399551.xls

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Moly-Cop Tools / 288399551.xls

Page 2

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where (% error) corresponds to the combined sampling and measuring error percentage.
The least-square minimization problem stated above may be linearized and solved through the Lagrange Multipliers
Method (see About ... in Cyclobal_Single).
Further refinement of the adjusted values so computed is achieved by imposing the condition that these values must
conform to the Plitt's Classification Efficiency curve : (see About ... in Cyclosim_Single)
Ei = Bpf + (1 - Bpf ) (1 - exp [ - 0.693 (di/d50c)m ])
with the aid of the Excel Subroutine Solver to minimize a least-square objective function with respect to parameters
Bpf, d50c and m.
Finally, the size distributions for the remaining streams of the circuit (fresh feed, mill feed and mill discharge) are
calculated on the basis of the adjusted values so obtained.
Data Input and Program Execution :
Most of the data required by the model must be defined in each corresponding unprotected white background cell inside the red double-lined border - of the here attached Data_File worksheet. Gray background cells contain the
results of the corresponding formulas there defined and are protected to avoid any accidental editing.
The remaining information required to run the program is entered in the Control_Panel worksheet, where the user is
requested to provide initial guesses of the Bpf, d50c and m parameters (see About ... in Cyclosim_Single). The Bpc
parameter is rarely used and was incorporated to take into account the possible short-circuit of coarse particles to the
overflow (as could be the case in highly pressurised cyclones). Finally, the user must specify the relative weighting
factors for the various feed, underflow and overflow streams plus the relative weighting factors for the size distribution
and percent solids measurements.
To run the program, select the objective function Cell E22 in Control_Panel and then, from the Tools Menu, select
Solver ..., then Min and then By Changing any combination of Cells C20:F20. Clicking on the Solve button will
execute the desired calculations.
Important Notice : Solver ... must be run every time any element of input data gets to be modified. Otherwise,
the current outputs are not valid.
Calculation results are summarized in the Reports worksheet.
An interesting feature of this routine is that the user has the option to save for later reference every analyzed data set
by copying the Data_File worksheet into as many as required Sample 1, Sample 2, etc. worksheets. For reprocessing
these data, simply copy the information back to the Data_File and re-run the Solver routine.
New Moly-Cop Tools users are invited to explore the brief comments inserted in each relevant cell, rendering the
whole utilization of the worksheets self-explanatory. Eventually, the user may wish to remove the view of the comments
by selecting Tools / Options / View / Comments / None.

Moly-Cop Tools / 288399551.xls

Page 3

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Moly-Cop Tools

TM

BALLBAL : Mass Balance Closure around a Ball Mill Grinding Circuit

Circuit Type

DIRECT

Remarks

Sample N

Balance circuito de molienda Molino # 1 , Fecha de muestreo 03/06/15

Mill Dimensions and Operating Conditions

Diameter
Length
Speed
Charge
ft
ft
% Critical
Filling,%
15.5
19.5
75.2
42.00
rpm
14.63

Balls
Filling,%
42.00

Cyclone Dimensions (inches) and Operating Pressure (psi)

Number
Diameter
Height
Inlet
Vortex
3
26.0
75.0
10.00
10.00

Interstitial
Slurry Filling,%
100.00

Apex
5.50

Lift
Angle, ()
30.9

1827
0
338
2165
5.3
2286

Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW

Charge
Volume,
m3
43.85

psi
6.90

Mill Charge Weight, tons

Apparent
Ball
Slurry
Density
Charge
Interstitial
Excess
ton/m3
203.89
37.74
0.00
5.511

Feedrate, ton/hr (dry)

275.4

Ore Density, ton/m3

Balls Density, ton/m3

3.00
7.75

EXPERIMENTAL SIZE DISTRIBUTIONS

i

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
0.25
4
8
10
14
20
28
35
48
65
100
150
200
270
325
400
-400

Totals
% Solids
Slurry Density, ton/m3
Weighting Factor

Moly-Cop Tools / 288399551.xls

Opening
25400
19050
12700
9500
6730
4750
2360
1700
1180
850
600
425
300
212
150
106
75
53
44
38
0

Mid-Size

ton/hr

Fresh Feed
% Retained % Passing

ton/hr

Mill Discharge
% Retained % Passing

100.00
21997
15554
10984
7996
5654
3348
2003
1416
1001
714
505
357
252
178
126
89
63
48
41
19

0.00
0.00
82.65
65.32
29.42
38.22
9.94
7.01
4.93
3.65
3.43
2.99
2.97
3.02
2.38
2.45
2.15
1.01
0.86
13.05
275.42

0.00
0.00
30.01
23.72
10.68
13.88
3.61
2.54
1.79
1.32
1.25
1.09
1.08
1.09
0.86
0.89
0.78
0.36
0.31
4.74
100.00

100.0
100.0
70.0
46.3
35.6
21.7
18.1
15.6
13.8
12.5
11.2
10.1
9.0
7.9
7.1
6.2
5.4
5.0
4.7

0.00

93.08
2.635
0.000

ton/hr

Cyclone Feed
% Retained % Passing

100.00
0.00
0.00
78.11
98.48
56.44
124.52
72.37
96.78
122.59
191.94
225.00
178.22
124.57
86.41
51.48
46.09
35.25
16.07
14.16
209.96
1828.43

0.00
0.00
4.27
5.39
3.09
6.81
3.96
5.29
6.70
10.50
12.31
9.75
6.81
4.73
2.82
2.52
1.93
0.88
0.77
11.48
100.00

100.0
100.0
95.7
90.3
87.3
80.4
76.5
71.2
64.5
54.0
41.7
31.9
25.1
20.4
17.6
15.1
13.1
12.3
11.5

0.00

80.30
2.152
1.000

0.00
0.00
89.87
113.31
64.94
143.28
83.27
111.36
141.06
220.85
258.89
205.06
143.33
99.43
59.24
53.03
40.56
18.49
16.29
241.58
2103.85

0.00
0.00
4.27
5.39
3.09
6.81
3.96
5.29
6.70
10.50
12.31
9.75
6.81
4.73
2.82
2.52
1.93
0.88
0.77
11.48
100.00

100.00
100.00
100.00
95.73
90.34
87.26
80.45
76.49
71.19
64.49
53.99
41.69
31.94
25.13
20.40
17.58
15.06
13.14
12.26
11.48
0.00

70.00
1.875
1.000

ton/hr

Cyclone U'flow
% Retained % Passing

ton/hr

Cyclone O'flow
% Retained % Passing

100.00
0.00
0.00
40.14
96.31
60.47
147.14
92.73
122.78
159.00
231.28
279.46
198.20
116.68
65.87
34.08
25.01
19.41
8.11
7.26
124.50
1828.43

0.00
0.00
2.20
5.27
3.31
8.05
5.07
6.71
8.70
12.65
15.28
10.84
6.38
3.60
1.86
1.37
1.06
0.44
0.40
6.81
100.00

100.0
100.0
97.8
92.5
89.2
81.2
76.1
69.4
60.7
48.1
32.8
21.9
15.5
11.9
10.1
8.7
7.7
7.2
6.8

0.00

76.83
2.050
1.000

100.00
0.00
0.00
0.00
0.00
0.00
0.00
0.19
1.28
3.22
5.93
18.19
24.88
32.63
32.84
20.83
24.84
12.65
6.27
5.52
86.16
275.42

0.00
0.00
0.00
0.00
0.00
0.00
0.07
0.46
1.17
2.15
6.60
9.03
11.85
11.92
7.56
9.02
4.59
2.28
2.00
31.28
100.00

100.0
100.0
100.0
100.0
100.0
100.0
99.9
99.5
98.3
96.1
89.5
80.5
68.7
56.7
49.2
40.2
35.6
33.3
31.3

0.00

39.77
1.361
1.000

10/01/2015 / 16:04:34

Moly-Cop Tools

TM

Ballbal_Direct : MASS BALANCE CLOSURE AROUND A BALL MILL GRINDING CIRCUIT

Sample N

0
1
1
1
1

Size Distributions
% Solids

1
1

Initial Guesses :
Bpf
Bpc
0.535
0.015

d50c
293.9

Obj. Function :

0.018

Classifier Constants :
a1
a2
a3
a4

4.11
0.856
51.82
1.205
1.129

Moly-Cop Tools / 288399551.xls

% Pas sing

100.00

Weighting Factors :
Streams :
Fresh Feed
Mill Discharge
Cyclone Feed
Cyclone U'flow
Cyclone O'flow

10.00

m
2.424

Mill Disc harge

Cyc lone U'flow
Cyc lone O'flow
Column F
Column I
Column J

1.00
10

100Particle Size, m icrons

1000

10000

Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.

10/01/2015 / 16:04:34

Moly-Cop Tools

TM

Remarks

Sample N

Balance circuito de molienda Molino # 1 , Fecha de muestreo 03/06/15

psi

6.90

# of Cyclones
Vortex
Apex

3
10.00
5.50

% Solids

79.97

ton/hr
F80

275.4
10591

kWh/ton
Wio

39.80 % Solids
51.80 % - Size malla 150
297.4 P80

Water,
m3/hr

8.30
17.19

Moly-Cop Tools / 288399551.xls / Flowsheet

Circ. Load
m3/hr

0.535 Bpf
0.474 Bpw

543.60
1382

Water,
m3/hr

356.6

% Solids

69.13

39.5

Gross kW
% Balls
% Critical
% Solids

2285.5
42.00
75.19
80.30

10/01/2015 / 16:04:34

Moly-Cop Tools

TM

Sample N

Cyclone
U'flow
1497.2
374.9
1872.1
874.0
2.142
57.1
80.0

Cyclone
O'flow
275.4
416.5
691.9
508.3
1.361
18.1
39.8

BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks : Balance circuito de molienda Molino # 1 , Fecha de muestreo 03/06/15

CIRCUIT MASS BALANCE

Configuration : DIRECT

Ore, ton/hr
Water, m3/hr
Slurry, ton/hr
Slurry, m3/hr
Slurry Dens., ton/m3
% Solids (by volume)
% Solids (by weight)

Fresh
Feed
275.4
20.5
295.9
112.3
2.635
81.8
93.1

Mill
Mill
Feed
Discharge
1772.6
1772.6
395.4
434.9
2168.0
2207.5
986.3
1025.7
2.198
2.152
59.9
57.6
81.8
80.3

Sump
Water
0.0
356.6
356.6
356.6
1.000
0.0
0.0

Cyclone
Feed
1772.6
791.5
2564.1
1382.3
1.855
42.7
69.1

Particle Size Distributions (Cummulative % Passing)

i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Mesh

Opening

1.05
0.742
0.525
0.371
0.25
4
8
10
14
20
28
35
48
65
100
150
200
270
325
400

25400
19050
12700
9500
6730
4750
2360
1700
1180
850
600
425
300
212
150
106
75
53
44
38

D80, microns

100.00
100.00
100.00
69.99
46.28
35.59
21.72
18.11
15.56
13.78
12.45
11.21
10.12
9.04
7.95
7.08
6.19
5.41
5.05
4.74

100.00
100.00
100.00
92.44
83.91
79.32
70.36
65.65
59.71
52.27
41.31
28.43
19.70
14.61
11.53
9.85
8.37
7.32
6.85
6.44

100.00
100.00
100.00
97.06
92.13
89.16
82.25
78.03
72.40
65.13
54.19
40.85
30.62
23.64
18.94
16.24
13.80
12.10
11.33
10.65

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
100.00
97.06
92.13
89.16
82.25
78.03
72.40
65.13
54.19
40.85
30.62
23.64
18.94
16.24
13.80
12.10
11.33
10.65

100.00
100.00
100.00
96.57
90.83
87.37
79.31
74.39
67.83
59.35
46.61
31.60
21.47
15.64
12.19
10.36
8.77
7.68
7.18
6.75

100.00
100.00
100.00
99.71
99.22
98.93
98.24
97.83
97.27
96.55
95.39
91.12
80.37
67.16
55.62
48.20
41.18
36.17
33.89
31.86

10591

5007

1985

1985

2513

297.4

Specific Energy Consumption :

Operational Work Index :

Moly-Cop Tools / 288399551.xls

8.30 KWH/ton (Gross)

17.19 KWH/ton

Page 7

10/01/2015 / 16:04:34

Moly-Cop Tools

TM

Sample N

BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks : Balance circuito de molienda Molino # 1 , Fecha de muestreo 03/06/15

CLASSIFIERS PERFORMANCE
Number of Cyclones :
Cyclone Dimensions, in :
Diameter
Height
Inlet
Vortex
Apex
Ore Density, ton/m3

Operating Conditions :
Feed Flowrate, m3/hr
Pressure, psi
D50 (corr.), microns
Water By-Pass, %
Solids By-Pass, %
Plitt's Parameter
Circulating Load, %

26.00
75.00
10.00
10.00
5.50
3.00

1382.3
6.9
293.9
47.4
53.5
2.42
544

Mass Balance around the Classifiers

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
0.25
4
8
10
14
20
28
35
48
65
100
150
200
270
325
400

Opening
25400
19050
12700
9500
6730
4750
2360
1700
1180
850
600
425
300
212
150
106
75
53
44
38

Ore, ton/hr
Water, m3/hr
Slurry, ton/hr
Slurry, m3/hr
Slurry Dens., ton/m3
% Solids (by volume)
% Solids (by weight)

Moly-Cop Tools / 288399551.xls

Mid-Size
21997
15554
10984
7996
5654
3348
2003
1416
1001
714
505
357
252
178
126
89
63
48
41
19

Size Distributions, % Passing

Feed
U'flow
O'flow
100.00
100.00
100.00
97.06
92.13
89.16
82.25
78.03
72.40
65.13
54.19
40.85
30.62
23.64
18.94
16.24
13.80
12.10
11.33
10.65

100.00
100.00
100.00
96.57
90.83
87.37
79.31
74.39
67.83
59.35
46.61
31.60
21.47
15.64
12.19
10.36
8.77
7.68
7.18
6.75

100.00
100.00
100.00
99.71
99.22
98.93
98.24
97.83
97.27
96.55
95.39
91.12
80.37
67.16
55.62
48.20
41.18
36.17
33.89
31.86

1772.6
791.5
2564.1
1382.3
1.855
42.7
69.1

1497.2
374.9
1872.1
874.0
2.142
57.1
80.0

275.4
416.5
691.9
508.3
1.361
18.1
39.8

Page 8

Classifier Efficiency
Actual
Corrected
0.985
0.985
0.985
0.985
0.985
0.985
0.985
0.985
0.985
0.983
0.950
0.837
0.706
0.619
0.573
0.552
0.542
0.539
0.538
0.535

1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.997
0.924
0.671
0.380
0.187
0.085
0.038
0.016
0.009
0.006
0.001

Classifier Constants
a1
a2
a3
a4

4.108
0.856
51.824
1.205
1.129

10/01/2015 / 16:04:34

Moly-Cop Tools / 288399551.xls

Page 9

10/01/2015 / 16:04:34

Moly-Cop Tools

TM

Sample N

BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks : Balance circuito de molienda Molino # 1 , Fecha de muestreo 03/06/15

BALL MILL PERFORMANCE

Diameter, ft
Length, ft
Speed, % Critical
App. Density, ton/m3
Charge Level, %
Balls Filling, %
Lift Angle, ()

15.5
19.5
75.2
5.51
42.0
42.0
30.9

Mill Power, kW (Gross)

Mill Power, kW (Net)
Throughput, ton/hr
% Solids (by weight)
Sp. Energy, KWH/ton
Reduction Ratio

2286
2165
1772.6
81.8
1.29
2.52

Size Distributions
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
0.25
4
8
10
14
20
28
35
48
65
100
150
200
270
325
400

Opening
25400
19050
12700
9500
6730
4750
2360
1700
1180
850
600
425
300
212
150
106
75
53
44
38

Mill
Feed

Mid-Size
21997
15554
10984
7996
5654
3348
2003
1416
1001
714
505
357
252
178
126
89
63
48
41
19

D80, microns

Moly-Cop Tools / 288399551.xls

Page 10

Mill
Discharge

100.00
100.00
100.00
92.44
83.91
79.32
70.36
65.65
59.71
52.27
41.31
28.43
19.70
14.61
11.53
9.85
8.37
7.32
6.85
6.44

100.00
100.00
100.00
97.06
92.13
89.16
82.25
78.03
72.40
65.13
54.19
40.85
30.62
23.64
18.94
16.24
13.80
12.10
11.33
10.65

5007

1985

10/01/2015 / 16:04:34

Number of Cyclones
Classifier Dimensions, inches.
DC
h
DI
DO
26
75
10
10
Classifier Constants

a2
a3
a4
4.1076647 0.856107 51.82379 1.205146
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

25400
19050
12700
9500
6730
4750
2360
1700
1180
850
600
425
300
212
150
106

Mid-Size

21997.05
15554.26
10984.08
7995.936
5653.981
3348.134
2002.998
1416.333
1001.499
714.1428
504.9752
357.0714
252.1904
178.3255
126.0952

3
DU
5.5

1.129126
5.436041
1.719352
8.590977
6.90
293.8699
0.473726
0.534897
0.015376
2.424402

Solids, tons
Water, m3/hr
Slurry, tons
Slurry, m3/hr
Solids Density, ton/m3
Slurry Density, ton/m3
% Solids (by volume)
% Solids (by weight)

Classifier
Efficiency

Cyclone
Feed
701.28
313.12
1014.401
546.8788
3
1.854892
42.7446
69.13

Cyclone
Feed

0.984624
0.984624
0.984624
0.984624
0.984624
0.984624
0.984624
0.984624
0.984624
0.983471
0.95037
0.836608
0.705863
0.61878
0.573233

Cyclone
O'flow
108.9619
164.79
273.7476
201.1063
3
1.361208
18.06042
39.80

ton/hr (model)
Cyclone Cyclone
U'flow
O'flow

0.00
0.00
61.82
103.72
62.42
145.46
88.71
118.52
152.99
230.08
280.76
215.22
146.71
99.02
56.79

Page 11

Cyclone
U'flow
592.32
148.33
740.6536
345.7725
3
2.142026
57.10128
79.97

0
0
60.86663
102.1268
61.45662
143.2213
87.34875
116.6996
150.6419
226.2782
266.8259
180.0579
103.554
61.27372
32.55546

0.00
0.00
0.95
1.59
0.96
2.24
1.36
1.82
2.35
3.80
13.93
35.17
43.15
37.75
24.24

% Retained (model)
Cyclone
Feed

0.00
0.00
2.94
4.93
2.97
6.91
4.22
5.63
7.27
10.94
13.35
10.23
6.97
4.71
2.70

17
18
19
20
21

75 89.16277
53 63.0476
44 48.29079
38 40.8901
0
19

0.551863
0.542299
0.53879
0.537502
0.535304
Total

Page 12

51.24
35.76
16.17
14.31
224.14

28.27549
19.39473
8.712976
7.693643
119.9811

22.96
16.37
7.46
6.62
104.16

2.44
1.70
0.77
0.68
10.65

2103.85

1776.96

326.89

100.00

% Retained (model)
Cyclone
Cyclone
U'flow
O'flow

0.00
0.00
3.43
5.75
3.46
8.06
4.92
6.57
8.48
12.73
15.02
10.13
5.83
3.45
1.83

0.00
0.00
0.29
0.49
0.29
0.68
0.42
0.56
0.72
1.16
4.26
10.76
13.20
11.55
7.41

Cyclone
Feed

% Passing (model)
Cyclone
Cyclone
U'flow
O'flow

100.00
100.00
100.00
97.06
92.13
89.16
82.25
78.03
72.40
65.13
54.19
40.85
30.62
23.64
18.94
16.24

100.00
100.00
100.00
96.57
90.83
87.37
79.31
74.39
67.83
59.35
46.61
31.60
21.47
15.64
12.19
10.36

100.00
100.00
100.00
99.71
99.22
98.93
98.24
97.83
97.27
96.55
95.39
91.12
80.37
67.16
55.62
48.20

Cyclone
Feed

% Passing (exp)
Cyclone Cyclone
U'flow
O'flow

100.00
100.00
100.00
97.06
92.13
89.16
82.25
78.03
72.40
65.13
54.19
40.85
30.62
23.64
18.94
16.24

Page 13

100.00
100.00
100.00
97.80
92.54
89.23
81.18
76.11
69.40
60.70
48.05
32.77
21.93
15.55
11.94
10.08

100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.93
99.47
98.30
96.14
89.54
80.51
68.66
56.73
49.17

(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
0.001
0.001
0.001
0.000
0.001
0.001
0.000
0.000
0.000
0.001

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

1.59
1.09
0.49
0.43
6.75

7.02
5.01
2.28
2.03
31.86

100.00

100.00

13.80
12.10
11.33
10.65

8.77
7.68
7.18
6.75

41.18
36.17
33.89
31.86

13.80
12.10
11.33
10.65

Page 14

8.71
7.65
7.21
6.81

40.15
35.56
33.29
31.28

0.000
0.000
0.000
0.000

0.000
0.000
0.000
0.000

0.001
0.000
0.000
0.000

0.000

0.000

Page 15

Overall
0.000

Page 16

Sample 1

Moly-Cop Tools

TM

BALLBAL : Mass Balance Clos

Circuit Type

DIRECT

Remarks

Base Case Example

Mill Dimensions and Operating Conditions

Diameter
Length
Speed
Charge
ft
ft
% Critical
Filling,%
18.5
22.0
72.0
38.00
rpm
12.82

Balls
Filling,%
38.00

Cyclone Dimensions (inches) and Operating Pressure (psi)

Number
Diameter
Height
Inlet
Vortex
10
20.0
75.0
3.50
7.50

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

Mid-Size

21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19

Totals
% Solids
Slurry Density, ton/m3
Weighting Factor

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

Interstitial
Slurry Filling,%
100.00

Apex
3.67

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

Page 17

psi
7.98

Mill Discharge
ton/hr

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

Sample 1

Page 18

Sample 1

L : Mass Balance Closure around a Ball Mill Grinding Circuit

Sample N

Lift
Angle, ()
35.0

3348
0
536
3885
10.0
4316

Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW

Charge
Volume,
m3
63.76

Mill Charge Weight, tons

Ball
Slurry
Charge
Interstitial
Excess
296.48
47.48
0.00

Feedrate, ton/hr (dry)

400.0

Ore Density, ton/m3

Balls Density, ton/m3

2.80
7.75

EXPERIMENTAL SIZE DISTRIBUTIONS

Mill Discharge
% 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

72.00
1.862
1.000

ton/hr

Cyclone Feed
% Retained % Passing

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

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

Page 19

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

Sample 1

Page 20

Sample 1

Apparent
Density
ton/m3
5.395

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

Circ.
Load

3.057
3.057
3.057
3.057
3.057
3.057
3.057
3.057
3.057
3.057
3.057
3.057

Circ. Load
W. Factors

40.00
1.346
1.000

Page 21

3.057

3.057

CL (ave)

3.057

Lambda

0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
(0.00000)
(0.00000)
(0.00000)
(0.00000)
(0.00000)
(0.00000)

0.00000

Sample 1

Page 22

Sample 1

NO DATA INPUT REQUIRED IN THIS SECTOR

Cyclone Feed (pre-adjusted)

ton/hr
% Retained % Passing

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

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

adj.

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

62.20

0.00

Cyclone O'flow (pre-adjusted)

ton/hr
% 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

Page 23

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

adj.

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
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)

40.00

(0.00)

Sample 1

Page 24

Sample 1

Cyclone U'flow (pre-adjusted)

ton/hr
% 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

adj.

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
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)

76.00

(0.00)

Page 25

Sample 1

Page 26

Size Distributions, %

Ball mill performance (Grinding circuit M1)

Date: June 3th, 2015

100.00
90.00

90.00

80.00

80.00

70.00

70.00

60.00

60.00

50.00

50.00

40.00

40.00

30.00

30.00

20.00

20.00

10.00
F r a c ti o n b e tw e n F e e d a n d D i sc h a r g e (U / F )

100.00

Discharge

0.00
10

100

1000

10.00

Feed

10000

0.00
100000

Particle Size

Classifier Efficiency (Grinding circuit M1)

Date: June 03th, 2015

1.000

Curva convencional para

0.900 ciclones crebb D-26B
0.800
0.700
0.600
0.500
0.400
0.300
0.200
Actual

0.100

Corrected

0.000
10

100
Particle Size

1000

0.600
0.500
0.400
0.300
0.200
Actual

0.100

Corrected

0.000
10

100
Particle Size

1000

)
100.00
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
100000

ected

1000

ected

1000