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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 :
i = [ 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.
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02/08/2016 / 03:30:33
A statistically sound weighting factor may be calculated as 100/(% error) 2; where (% error) corresponds to the
combined sampling and measuring error percentage. Weighting factors must never be set equal to zero.
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 distribution of the cyclone feed stream may be calculated on the basis of the adjusted values so
obtained for the fresh feed and mill discharge streams.
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 formula 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 pressurized 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.
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02/08/2016 / 03:30:33
Page 4
02/08/2016 / 03:30:33
Moly-Cop Tools
TM
(Version 3.0)
100
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 :
Classifier Constants :
a1
a2
a3
a4
d50c
194.4
% Passing
10
m
1.451
0.003
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.
02/08/2016 / 03:30:33
Moly-Cop Tools
TM
(Version 3.0)
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
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
Totals
% Solids
Slurry Density, ton/m3
Weighting Factor
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
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
Cyclone Feed
% Retained % Passing
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
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
02/08/2016 / 03:30:33
Moly-Cop Tools
TM
(Version 3.0)
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
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
02/08/2016 / 03:30:33
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
Cyclone
Cyclone
Cyclone
Water
Feed
U'flow
O'flow
0.0
1939.8
1539.8
400.0
466.4
1086.2
486.2
600.0
466.4
3026.0
2026.0
1000.0
466.4
1779.0
1036.2
742.9
1.000
1.701
1.955
1.346
0.0
38.9
53.1
19.2
0.0
64.1
76.0
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
D80, microns
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
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 8
02/08/2016 / 03:30:33
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 9
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
0.950
Bpc
0.000
02/08/2016 / 03:30:33
Page 10
02/08/2016 / 03:30:33
Sample N
BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks :
18.5
22.0
72.0
5.39
38.0
38.0
35.0
4316
3884
1539.8
76.0
2.80
3.85
2.34
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
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
Mill
Feed
Mid-Size
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
D80, microns
Page 11
Mill
Discharge
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
02/08/2016 / 03:30:33
Number of Cyclones
10
Classifier Dimensions, inches.
DC
h
DI
DO
DU
20
75
3.5
7.5 4.054711
Classifier Constants
a2
a3
a4
9.6794805 1.401179 54.94513 0.523572 0.950075
Circulating Load, CL
3.849413
Slurry Split, S
1.394819
Cyclone Pressure, ft
12.77407
Cyclone Pressure, lb/in2
9.41
Corrected Cut Size, d50c, microns
194.3752
Water By-Pass
0.447633
Fines By-Pass
0.425285
Coarse By-Pass
4.05E-005
Plitt's Parameter
1.451339
Opening
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
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
Classifier
Efficiency
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
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
ton/hr (model)
Cyclone Cyclone
U'flow
O'flow
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
Page 12
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
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
Cyclone
Feed
% Retained (model)
Cyclone
Cyclone
U'flow
O'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
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
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
17
18
19
20
21
106 126.0952
75 89.16277
53 63.0476
38 44.87761
0
19
0.602932
0.540441
0.497972
0.470827
0.438754
Total
Page 13
99.33
76.35
57.98
42.43
333.22
59.88834
41.26454
28.8701
19.97567
146.1994
39.44
35.09
29.11
22.45
187.02
5.12
3.94
2.99
2.19
17.18
3.89
2.68
1.87
1.30
9.49
9.86
8.77
7.28
5.61
46.75
1939.79
1539.79
400.01
100.00
100.00
100.00
Cyclone
Feed
% Passing (model)
Cyclone
Cyclone
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
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
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
% 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
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
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
(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
Page 14
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
26.29
22.35
19.37
17.18
15.35
12.67
10.79
9.49
68.41
59.64
52.37
46.75
26.29
22.35
19.37
17.18
15.35
12.67
10.79
9.49
68.41
59.64
52.37
46.75
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
Page 15
Overall
0.000