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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 :
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 d i.
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 :
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;
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)
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.
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.
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.
Sample N 1
100
Weighting Factors :
Streams :
Fresh Feed 0
Mill Discharge 1
Cyclone Feed 1
Cyclone U'flow 1
Cyclone O'flow 1
% Pass ing
Size Distributions 1 10
% Solids 1
Initial Guesses :
Bpf Bpc d50c m Mill Disc harge
0.109 0.002 66.8 0.794 4 Cyc lone U'flow
Cyc lone O'flow
Obj. Function : 1.166 Column F
Column I
Column J
Classifier Constants :
a1 4.15 1
10 100 1000 10000
a2 0.383
Particle Size , m icrons
a3 30.89
a4 -0.024
0.252 Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
Sample N 1
45.74 % Solids
39.20 % - Size 18
psi 9.60 195.4 P80
# of Cyclones 11
Vortex 8.00 Circ. Load 402.65
Apex 5.25 0.109 Bpf m3/hr 5958
0.433 Bpw
% Solids 81.63
Water,
m3/hr 1095.9
ton/hr 1668.2 Water, 509.8
F80 2554 m3/hr
Gross kW 8355.1
kWh/ton 5.01 % Balls 34.00
Wio 9.68 % Critical 65.20
% Solids 77.78
% Solids 70.60
CLASSIFIERS PERFORMANCE
Size Distributions
Mill Mill
i Mesh Opening Mid-Size Feed Discharge
Number of Cyclones 11
Classifier Dimensions, inches.
DC h DI DO DU
26 90 9.8 8 5.25
Classifier Constants
a2 a3 a4 Cyclone Cyclone Cyclone
4.1465086 0.3826806 30.89206 -0.024084 0.2521319 Feed U'flow O'flow
Circulating Load, CL 4.0264904 Solids, tons 715.08 572.82 142.2622
Slurry Split, S 1.4120135 Water, m3/hr 297.74 128.94 168.79
Cyclone Pressure, ft 11.121472 Slurry, tons 1012.8152 701.76036 311.05482
Cyclone Pressure, lb/in2 9.60 Slurry, m3/hr 508.05313 297.41868 210.63445
Corrected Cut Size, d50c, microns 66.762272 Solids Density, ton/m3 3.4 3.4 3.4
Water By-Pass 0.4330788 Slurry Density, ton/m3 1.9935222 2.3595033 1.4767519
Fines By-Pass 0.109193 % Solids (by volume) 41.396757 56.645969 19.864662
Coarse By-Pass 0.0023023 % Solids (by weight) 70.60 81.63 45.74
Plitt's Parameter 0.7935672
ton/hr (model) % Retained (model)
Opening Mid-Size Classifier Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone
Efficiency Feed U'flow O'flow Feed U'flow O'flow
1 19050
2 12700 15554.26 0.9976977 31.41 31.335344 0.07 0.40 0.50 0.00
3 9500 10984.079 0.9976977 38.67 38.579035 0.09 0.49 0.61 0.01
4 6350 7766.917 0.9976977 48.34 48.229015 0.11 0.61 0.77 0.01
5 4750 5492.0397 0.9976977 35.07 34.98983 0.08 0.45 0.56 0.01
6 3350 3989.0475 0.9976977 66.66 66.505353 0.15 0.85 1.06 0.01
7 2360 2811.761 0.9976964 99.84 99.607108 0.23 1.27 1.58 0.01
8 1700 2002.9978 0.9976679 121.06 120.77848 0.28 1.54 1.92 0.02
9 1180 1416.3333 0.9973428 201.23 200.69545 0.53 2.56 3.19 0.03
10 850 1001.4989 0.9953679 268.07 266.82918 1.24 3.41 4.23 0.08
11 600 714.14284 0.9882598 425.15 420.15452 4.99 5.40 6.67 0.32
12 425 504.97525 0.9695481 843.91 818.2099 25.70 10.73 12.99 1.64
13 300 357.07142 0.9331394 1099.78 1026.2523 73.53 13.98 16.29 4.70
14 212 252.1904 0.8762015 1266.09 1109.3478 156.74 16.10 17.61 10.02
15 150 178.32555 0.801662 987.72 791.81892 195.90 12.56 12.57 12.52
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Overall
1.877 0.843 1.360
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