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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 di.
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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Moly-Cop Tools
TM
(Version 2.0)
0
1
1
1
1
Size Distr.
% Solids
1
1
Initial Guesses :
Bpf
Bpc
0.425
0.000
d50c
194.4
Obj. Function :
0.003
Classifier Constants :
a1
a2
a3
a4
9.68
1.401
54.95
0.524
0.950
% Pas s ing
100.00
Weighting Factors
Streams :
Fresh Feed
Mill Discharge
Cyclone Feed
Cyclone U'flow
Cyclone O'flow
10.00
m
1.451
Mill Discharge
Cyclone U'flow
Cyclone O'flow
Column F
1.00
10
100
1000
10000
Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
09/21/2015 / 03:03:06
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
Mesh
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
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
-400
Totals
% Solids
Slurry Density, ton/m3
Weighting Factor
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
09/21/2015 / 03:03:06
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
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
09/21/2015 / 03:03:06
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 8
09/21/2015 / 03:03:06
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
09/21/2015 / 03:03:06
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 10
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
09/21/2015 / 03:03:06
C
Number of Cyclones
Classifier Dimensions, inches.
DC
h
DI
DO
20
75
3.5
7.5
Classifier Constants
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
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
10
DU
4.054711
0.950075
3.849413
1.394819
12.77407
9.41
194.3752
0.447633
0.425285
4.0E-005
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)
Classifier
Efficiency
Cyclone
Feed
193.98
108.63
302.6044
177.9034
2.8
1.700948
38.94155
64.10
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
Cyclone
O'flow
40.00057
60.00
100.0014
74.28678
2.8
1.346154
19.23077
40.00
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 11
Cyclone
U'flow
153.98
48.62
202.6029
103.6166
2.8
1.955314
53.07297
76.00
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
C
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 12
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
Cyclone
Feed
% Passing (exp)
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
90.72
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
Page 13
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
C
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
Page 14
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Overall
0.000