Moly-Cop Tools, Version 2.

0
About the CycloBal_Single Spreadsheet ...

Scope :
The CycloBal_Single spreadsheet was designed to compute the Size-by-Size Mass Balance around a Hydrocyclone
Classifier on the basis of actual plant measurements from any given existing installation.
Theoretical Framework :
Whenever actual data are collected in a plant environment, they will invariably be affected by natural experimental and
measurement errors, in such a way that - in the particular case of hydrocyclones - the basic mass balance equation for
the mass flowrate of particles of size di :
fiF F = fiU U + fiO O

???

, for i = 1,n

will never be satisfied. In the above expression F, U and O represent the mass flowrate of solids in the cyclone feed,
underflow and overflow streams, respectively. Similarly, fiF, fiU and fiO represent the fraction of those total respective
streams corresponding to particles of size di.
The Cyclobal_Single routine allows for the calculation of a whole new set of corresponding adjusted or fitted values fiF, fiU
and fiO, such that the objective functions :
i = [ wF (fiF - fiF)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 :
f iF F = f iU U + f iO O

, for i = 1,n

where wF, 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 F, U and O are calculated as :
F = F
U = F [CL / (1 + CL)]
O = F / (1 + CL)
and the Circulating Load CL is estimated from :
CL = { usd

[(fiO - fiF) / (fiF - fiU)] + ufs (1/fSO - 1/fSF) / (1/fSF -1/fSU) } / (usd + ufs)

all i

where fsF, fsU and fsO are the weight fractions of total solids in the 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.

Moly-Cop Tools / 274953687.xls

06/30/2015 / 01:13:24

Moly-Cop Tools, Version 2.0

About the Cyclobal_Single Spreadsheet ...
The least-square minimization problem stated above may be linearized and solved through the Lagrange Multipliers
Method to obtain :
fiF F = fiF F - /wF
fiU U = fiU U + /wU
fiO O = fiO O + /wO

; for n = 1, n

with the Lagrange multiplier given by :

= ( fiF F - fiU U + fiO O) / (1/wF + 1/wU + 1/wO)
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 B pf,
d50c and the Plitt's Parameter, m.
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 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, on the Control_Panel worksheet, select the objective function Cell E22 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.

Moly-Cop Tools / 274953687.xls

06/30/2015 / 01:13:25

Moly-Cop Tools / 274953687.xls

06/30/2015 / 01:13:25

Moly-Cop Tools

TM

(Version 2.0)
Cyclobal_Single : HYDROCYLONE MASS BALANCE CLOSURE
1
100.00

Weighting Factors :
Streams :
Cyclone Feed
Cyclone U'flow
Cyclone O'flow

1
1
1

Size Distributions
% Solids

1
1

Initial Guesses :
Bpf
Bpc
0.372
0.000

d50c
179.8

Obj. Function :

0.002

Classifier Constants :
a1
a2
a3
a4

9.68
1.401
54.95
0.523
0.950

Moly-Cop Tools / 274953687.xls

m
1.618

% Pas sing

Sample N

10.00

4
Cyclone Feed
Cyclone U'flow
Cyclone O'flow
Column E
Column F
1.00
10

100

1000

10000

Particle Size, m icrons

06/30/2015 / 01:13:25

Moly-Cop Tools

TM

(Version 2.0)
HYDROCYCLONE MASS BALANCE CLOSURE

Remarks

Base Case Example

Cyclone Dimensions, inches

Number
Diameter
Height
10
20.0
75.0
60.0
Default Values:

Sample N

Inlet
3.50
5.00

Vortex
7.50
7.00

Ore Density, ton/m3

Dry Feedrate, ton/hr
Volumetric Flow, m3/hr
Cyclones Pressure, psi

Apex
3.67
3.75

2.80
1622.8
1565.7
7.98

EXPERIMENTAL SIZE DISTRIBUTIONS

i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

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
-400

Totals
% Solids
Weighting Factor

Moly-Cop Tools / 274953687.xls

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
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

Cyclone Feed
% Retained % Passing
100.00
0.00
100.00
1.12
98.88
2.56
96.32
2.51
93.81
2.28
91.53
2.37
89.16
2.72
86.44
3.16
83.28
4.13
79.16
4.86
74.30
6.20
68.10
7.57
60.53
8.76
51.77
8.85
42.92
7.74
35.18
6.10
29.08
4.51
24.57
3.33
21.24
2.40
18.84
18.84
0.00
100.00
62.20
1.000

ton/hr
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

Cyclone U'flow
% Retained % Passing
100.00
0.00
100.00
1.49
98.51
3.39
95.12
3.33
91.79
3.03
88.76
3.15
85.61
3.61
82.00
4.19
77.81
5.48
72.34
6.45
65.89
8.22
57.67
9.89
47.78
10.73
37.05
9.52
27.54
7.02
20.52
4.65
15.87
2.98
12.89
1.97
10.91
1.33
9.59
9.59
0.00
100.00
76.00
1.000

ton/hr
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

Cyclone O'flow
% Retained % Passing
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.00
100.00
0.02
99.97
0.49
99.49
2.73
96.76
6.81
89.96
9.95
80.00
10.52
69.49
9.20
60.29
7.46
52.82
5.69
47.13
47.13
0.00
100.00
40.00
1.000

06/30/2015 / 01:13:25

Moly-Cop Tools

TM

(Version 2.0)
CYCLOBAL

Sample N

Cyclone Mass Balance Closure

Remarks : Base Case Example

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

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

Moly-Cop Tools / 274953687.xls

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
3.67
2.80

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

Size Distributions, % Passing

Feed
U'flow
O'flow
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

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

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
80.01
69.49
60.29
52.82
47.14

1273

2022

150.0

1622.8
986.2
2609.0
1565.7
1.666
37.0

1222.9
386.2
1609.0
822.9
1.955
53.1

400.0
600.0
1000.0
742.8
1.346
19.2

Page 6

1565.7
8.0
179.8
39.2
37.2
1.62
306

Classifier Efficiency
Actual
Corrected
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.999
0.984
0.923
0.811
0.683
0.575
0.497
0.447
0.416
0.383

1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.998
0.975
0.878
0.698
0.495
0.323
0.200
0.119
0.071
0.018

Classifier Constants
a1
9.680
a2
1.401
a3
54.946
a4
0.523

0.950

06/30/2015 / 01:13:25

% Solids (by weight)

Moly-Cop Tools / 274953687.xls

62.2

76.0

Page 7

40.0

Bpc

0.000

06/30/2015 / 01:13:25

Moly-Cop Tools

TM

CYCLOBAL

Sample N

Raw Experimental Data

Remarks : Base Case Example

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

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)

Moly-Cop Tools / 274953687.xls

10

Operating Conditions :
Feed Flowrate, m3/hr
Pressure, psi

20.00
75.00
3.50
7.50
3.67
2.80

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

1565.7
8.0

Circulating Load, %

306

Size Distributions, % Passing

EXPERIMENTAL VALUES
FITTED VALUES
Feed
U'flow
O'flow
Feed
U'flow
O'flow
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

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

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

1622.8
986.2
2609.0
1565.7
1.666
37.02
62.2

1222.8
386.2
1609.0
822.9
1.955
53.07
76.0

400.0
600.0
1000.0
742.9
1.346
19.23
40.0

Page 8

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

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

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
80.01
69.49
60.29
52.82
47.14

06/30/2015 / 01:13:25

C
Number of Cyclones
Classifier Dimensions, inches.
DC
h
DI
DO
20
75
3.5
7.5
Classifier Constants
a1
a2
a3
a4
9.6796053 1.401158 54.94554 0.523394
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
3.669508

0.950027
3.057176
1.107773
11.05621
7.98
179.7869
0.39159
0.372021
3.7E-005
1.618198

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
162.28
98.62
260.9006
156.5749
2.8
1.666299
37.01662
62.20

Cyclone
Feed

0.999963
0.999963
0.999963
0.999963
0.999963
0.999963
0.999963
0.999963
0.999963
0.999954
0.998978
0.984213
0.923339
0.810506
0.683078

Cyclone
O'flow
39.99936
60.00
99.99839
74.28452
2.8
1.346154
19.23077
40.00

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

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

Page 9

Cyclone
U'flow
122.29
38.62
160.9022
82.29035
2.8
1.955298
53.07213
76.00

0
18.17136
41.48849
40.7549
37.00468
38.53055
44.13365
51.20622
66.97369
78.82483
100.5028
120.9213
131.2116
116.4063
85.79757

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.10
1.94
10.89
27.22
39.81

Cyclone
Feed

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

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

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

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.48
2.72
6.80
9.95

C
17
18
19
20
21

106 126.0952
75 89.16277
53 63.0476
38 44.87761
0
19

0.574952
0.497426
0.446995
0.416432
0.38338
Total

Page 10

98.97
73.25
53.99
38.98
305.76

56.90014
36.43535
24.13387
16.23184
117.2217

42.06
36.81
29.86
22.75
188.54

6.10
4.51
3.33
2.40
18.84

4.65
2.98
1.97
1.33
9.59

10.52
9.20
7.46
5.69
47.14

1622.84

1222.85

399.99

100.00

100.00

100.00

Cyclone
Feed

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

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

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

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
80.01

Cyclone
Feed

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

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

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

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

(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 11

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
29.08
24.57
21.24
18.84

15.87
12.89
10.91
9.59

69.49
60.29
52.82
47.14

29.08
24.57
21.24
18.84

15.87
12.89
10.91
9.59

69.49
60.29
52.82
47.13

0.000
0.000
0.000
0.000

Page 12

0.000
0.000
0.000
0.000

0.000
0.000
0.000
0.000

0.000

0.000

Overall
0.000