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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 :
i = [ 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;
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Page 2
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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 error 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 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 E23 in Control_Panel and then, from the Tools Menu, select Solver
..., then Min and then By Changing any combination of Cells C21:F21. 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.
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.
Page 3
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Page 4
11/09/2015 / 13:36:23
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 Distributions
% Solids
1
1
Initial Guesses :
Bpf
Bpc
0.275
0.131
Obj. Function :
Classifier Constants :
a1
a2
a3
a4
d50c
124.3
% Passing
10
m
1.591
49.166
11.08
2.392
30.17
0.107
1.328
1
10
100
1000
10000
Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
11/09/2015 / 13:36:23
Moly-Cop Tools
TM
(Version 3.0)
DIRECT
Remarks
Balls
Filling,%
38.00
Interstitial
Slurry Filling,%
100.00
Apex
3.50
4.6
Lift
Angle, ()
33.8
113
0
22
135
10.0
150
Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW
psi
11.00
Mesh
Opening
1"
3/4"
5/8"
1/2"
3/8"
1/4"
4
6
8
25400
19050
15875
12700
9500
6700
4750
3350
2360
Mid-Size
21997
17390
14199
10984
7978
5641
3989
2812
ton/hr
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Fresh Feed
% Retained % Passing
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
100.00
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
ton/hr
Mill Discharge
% Retained % Passing
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
100.00
100.00
100.00
100.00
100.00
100.00
ton/hr
Cyclone Feed
% Retained
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
11/09/2015 / 13:36:23
10
11
12
13
14
15
16
17
18
19
20
21
10
14
20
28
35
48
65
100
150
200
325
-325
Totals
% Solids
Slurry Density, ton/m3
Weighting Factor
1700
1180
850
600
425
300
212
150
106
75
44
0
2003
1416
1001
714
505
357
252
178
126
89
57
22
0.00
0.00
0.00
0.00
0.00
66.24
3.52
3.10
5.69
3.77
6.86
10.81
100.00
0.00
0.00
0.00
0.00
0.00
66.24
3.52
3.10
5.69
3.77
6.86
10.81
100.00
100.0
100.0
100.0
100.0
100.0
33.8
30.2
27.1
21.4
17.7
10.8
0.00
98.00
3.065
0.000
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
68.63
10.68
79.31
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
86.54
13.46
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
13.5
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
155.17
24.14
179.31
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
86.54
13.46
100.00
83.00
2.329
1.000
11/09/2015 / 13:36:23
Charge
Volume,
m3
3.66
100.0
3.20
7.80
Apparent
Density
ton/m3
5.6
ton/hr
Cyclone U'flow
% Retained % Passing
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
100.00
100.00
100.00
100.00
100.00
100.00
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
0.00
0.00
0.00
0.00
0.00
0.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
11/09/2015 / 13:36:23
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
13.46
0.00
60.00
1.702
1.000
0.37
0.97
2.41
6.71
12.01
14.42
14.04
7.65
8.25
3.41
3.93
5.13
79.31
0.47
1.23
3.04
8.46
15.14
18.18
17.71
9.65
10.41
4.30
4.95
6.47
100.00
99.53
98.30
95.27
86.81
71.67
53.49
35.78
26.13
15.72
11.42
6.47
0.00
86.00
2.446
1.000
0.17
0.40
0.94
1.85
3.99
5.73
11.03
9.24
11.23
10.89
15.42
29.10
100.00
0.17
0.40
0.94
1.85
3.99
5.73
11.03
9.24
11.23
10.89
15.42
29.10
100.00
99.8
99.4
98.5
96.6
92.6
86.9
75.9
66.6
55.4
44.5
29.1
0.00
40.00
1.379
1.000
11/09/2015 / 13:36:23
Moly-Cop Tools
TM
(Version 3.0)
Sample N
Remarks
psi
11.00
# of Cyclones
Vortex
Apex
1
7.00
3.50
% Solids
75.73
ton/hr
F80
100.0
396
kWh/ton
Wio
41.49 % Solids
79.86 % - Size 18
106.8 P80
0.275 Bpf
0.207 Bpw
Water,
m3/hr
1.50
3.23
Circ. Load
m3/hr
115.10
245
Water,
m3/hr
133.9
% Solids
54.73
5.1
Gross kW
% Balls
% Critical
% Solids
150.0
38.00
76.00
83.00
11/09/2015 / 13:36:23
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
100.0
2.0
102.0
33.3
3.065
93.9
98.0
Mill
Mill
Feed
Discharge
215.1
215.1
38.9
44.1
254.0
259.2
106.1
111.3
2.393
2.329
63.3
60.4
84.7
83.0
Sump
Cyclone
Cyclone
Cyclone
Water
Feed
U'flow
O'flow
0.0
215.1
115.1
100.0
133.9
177.9
36.9
141.0
133.9
393.0
152.0
241.0
133.9
245.1
72.9
172.3
1.000
1.603
2.086
1.399
0.0
27.4
49.4
18.1
0.0
54.7
75.7
41.5
Mesh
Opening
1 1"
2 3/4"
3 5/8"
4 1/2"
5 3/8"
6 1/4"
7
8
9
10
11
12
13
14
15
16
17
18
19
20
4
6
8
10
14
20
28
35
48
65
100
150
200
325
25400
19050
15875
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
44
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
33.76
30.24
27.14
21.45
17.67
10.81
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.83
99.38
98.31
95.55
90.41
53.25
44.20
38.41
31.60
27.33
10.20
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.80
99.29
98.05
94.88
88.96
81.50
72.22
65.97
58.76
53.46
17.20
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
100.00
100.00
100.00
100.00
100.00
100.00
99.80
99.29
98.05
94.88
88.96
81.50
72.22
65.97
58.76
53.46
17.20
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.67
98.85
96.84
91.69
82.08
70.18
56.32
48.20
40.42
35.73
9.67
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.94
99.80
99.45
98.56
96.87
94.54
90.52
86.42
79.86
73.87
25.86
396
392
284
284
401
106.8
D80, microns
Specific Energy Consumption :
Operational Work Index :
Page 11
11/09/2015 / 13:36:23
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
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
6.50
7.00
3.50
3.20
245.1
11.0
124.3
20.7
27.5
1.59
115
Mesh
i
1 1"
2 3/4"
3 5/8"
4 1/2"
5 3/8"
6 1/4"
7
8
9
10
11
12
13
14
15
16
17
18
19
20
4
6
8
10
14
20
28
35
48
65
100
150
200
325
Opening
25400
19050
15875
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
44
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
17390
14199
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
57
22
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.67
98.85
96.84
91.69
82.08
70.18
56.32
48.20
40.42
35.73
9.67
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.94
99.80
99.45
98.56
96.87
94.54
90.52
86.42
79.86
73.87
25.86
215.1
177.9
393.0
245.1
1.603
27.4
54.7
115.1
36.9
152.0
72.9
2.086
49.4
75.7
100.0
141.0
241.0
172.3
1.399
18.1
41.5
Page 12
Classifier Efficiency
Actual
Corrected
0.869
0.869
0.869
0.869
0.869
0.869
0.869
0.869
0.869
0.869
0.869
0.869
0.868
0.854
0.799
0.696
0.577
0.474
0.384
0.301
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.998
0.976
0.882
0.708
0.508
0.335
0.184
0.043
Classifier Constants
a1
11.082
a2
2.392
a3
30.166
a4
0.107
1.328
Bpc
0.131
11/09/2015 / 13:36:23
Page 13
11/09/2015 / 13:36:23
Sample:
BALLBAL
Grinding Circuit Mass Balance Estimator
Remarks:
6.0
12.0
76.0
5.61
38.0
38.0
33.8
150
135
215.1
84.7
0.70
1.38
3.59
Size Distributions
i
Mesh
1 1"
2 3/4"
3 5/8"
4 1/2"
5 3/8"
6 1/4"
7
8
9
10
11
12
13
14
15
16
17
18
19
20
4
6
8
10
14
20
28
35
48
65
100
150
200
325
Opening
25400
19050
15875
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
44
Mill
Feed
Mid-Size
21997
17390
14199
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
57
22
D80, microns
Page 14
Mill
Discharge
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.83
99.38
98.31
95.55
90.41
53.25
44.20
38.41
31.60
27.33
10.20
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.80
99.29
98.05
94.88
88.96
81.50
72.22
65.97
58.76
53.46
17.20
392
284
11/09/2015 / 13:36:23
Number of Cyclones
1
Classifier Dimensions, inches.
DC
h
DI
DO
DU
26
75
6.5
7
3.5
Classifier Constants
a2
a3
a4
11.082009 2.3924081 30.166214 0.1066485 1.3284778
Circulating Load, CL
1.1509653
Slurry Split, S
0.4228176
Cyclone Pressure, ft
15.845654
Cyclone Pressure, lb/in2
11.00
Corrected Cut Size, d50c, microns
124.2839
Water By-Pass
0.2072871
Fines By-Pass
0.2753764
Coarse By-Pass
0.1311569
Plitt's Parameter
1.5907261
Opening
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
25400
19050
15875
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
Mid-Size
Classifier
Efficiency
21997.045
17390.191
14199.032
10984.079
7978.095
5641.3651
3989.0475
2811.761
2002.9978
1416.3333
1001.4989
714.14284
504.97525
357.07142
252.1904
0.8688431
0.8688431
0.8688431
0.8688431
0.8688431
0.8688431
0.8688431
0.8688431
0.8688431
0.8688431
0.8688431
0.8688348
0.8679008
0.8543726
0.7987334
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
ton/hr (model)
Cyclone Cyclone
U'flow
O'flow
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.36
0.91
2.22
5.68
10.62
13.37
16.64
Page 15
0
0
0
0
0
0
0
0
0.3135077
0.7921238
1.9309032
4.9362275
9.2170135
11.424707
13.294031
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.05
0.12
0.29
0.75
1.40
1.95
3.35
Cyclone
Feed
% Retained (model)
Cyclone
Cyclone
U'flow
O'flow
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.20
0.51
1.24
3.17
5.92
7.46
9.28
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.33
0.83
2.01
5.14
9.61
11.91
13.86
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.06
0.14
0.35
0.89
1.68
2.34
4.02
17
18
19
20
21
150
106
75
44
0
178.32555
126.0952
89.162773
57.445626
22
0.6955009
0.5768161
0.4744378
0.3844301
0.3009842
Total
Page 16
11.21
12.93
9.49
65.02
30.84
7.7962592
7.4602389
4.5030688
24.996724
9.2824212
3.41
5.47
4.99
40.03
21.56
6.25
7.21
5.29
36.26
17.20
8.13
7.78
4.69
26.05
9.67
4.09
6.57
5.98
48.01
25.86
179.31
95.95
83.36
100.00
100.00
100.00
Cyclone
Feed
% Passing (model)
Cyclone
Cyclone
U'flow
O'flow
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.80
99.29
98.05
94.88
88.96
81.50
72.22
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.67
98.85
96.84
91.69
82.08
70.18
56.32
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.94
99.80
99.45
98.56
96.87
94.54
90.52
Cyclone
Feed
% Passing (exp)
Cyclone Cyclone
U'flow
O'flow
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.80
99.29
98.05
94.88
88.96
81.50
72.22
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.53
98.30
95.27
86.81
71.67
53.49
35.78
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.83
99.43
98.49
96.64
92.65
86.92
75.88
(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
0.021
0.000
0.309
0.000
2.715
0.000
31.623
0.000
211.323
0.000 973.581
0.000 3296.500
Page 17
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.013
0.138
0.952
3.947
20.826
76.897
371.964
65.97
58.76
53.46
17.20
48.20
40.42
35.73
9.67
86.42
79.86
73.87
25.86
65.97
58.76
53.46
17.20
26.13
15.72
11.42
6.47
66.65
55.42
44.53
29.10
0.000
0.000
0.000
0.000
7131.849 880.519
24683.759 1945.454
45300.057 4344.273
2455.153 124.274
4425.626
Page 18
408.908
Overall
2417.267