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Moly--Cop Tools
Moly
Moly--Cop Tools
Moly
DE QU SE TRATA ?
Moly-Cop Tools
MolyLA VENTAJA
TM
: Theoretical Framework
Tamao de Particula
d = (d1 * d2)0.5
Moly-Cop Tools
TM
: Theoretical Framework
DISTRIBUCION DE TAMAOS
100
80
% Retained
%
% Passing
10
10
100
1000
Particle Size, mm
Moly-Cop Tools
TM
: Theoretical Framework
D80
10000
TAREA DE MOLIENDA
100
% Passing
80
Product
Feed
10
10
100
P80
1000
Particle Size, mm
Moly-Cop Tools
TM
: Theoretical Framework
F80
10000
DISTRIBUCION DE TAMAOS
Utilities_Size Distribution
Moly-Cop Tools TM
PARTICLE SIZE DISTRIBUTION
Sample 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Mesh
#
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
-400
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0
TOTAL
400.00
Retained
Weight
grs
%
0.00
21.02
13.24
31.86
62.72
61.77
46.39
30.20
18.25
13.71
9.04
7.76
6.62
6.03
5.54
5.16
4.85
4.53
4.25
3.81
43.25
5.26
3.31
7.97
15.68
15.44
11.60
7.55
4.56
3.43
2.26
1.94
1.66
1.51
1.39
1.29
1.21
1.13
1.06
0.95
10.81
400.00
100.00
(Dry)
Cumm.
Passing
%
100.00
94.75
91.44
83.47
67.79
52.35
40.75
33.20
28.64
25.21
22.95
21.01
19.36
17.85
16.46
15.17
13.96
12.83
11.77
10.81
100
Test ID :
10
1
10
100
1000
10000
100000
D80 =
8847
mm
D50 =
4456
mm
Moly-Cop Tools
TM
: Theoretical Framework
A mas kWh/ton
kWh/ton,, menor P80 !
Leyes de la Molienda
Ley de
Bond
1
1
E 10 *Wi *
P80 F 80
Moly-Cop Tools
TM
: Theoretical Framework
Leyes de la Molienda
Ley de
Bond
P
E
M
En la expresin anterior el par F80 y P80 se les denomina tarea de molienda; as mismo
permite estimar la energa (Kwhr) requerida para moler cada unidad (ton) de mineral.
Resulta Obvio que un aumento en la potencia (P), debiera traducirse en un aumento de
la capacidad (M)
Moly-Cop Tools
TM
: Theoretical Framework
Ley de Bond
12
11
10
9
8
7
Feed Size
4000 mm
2000 mm
1000 mm
4
80
100
120
140
160
180
200
Product Size, mm
Moly-Cop Tools
TM
: Theoretical Framework
220
240
260
Moly-Cop Tools
TM
: Theoretical Framework
Moly-Cop Tools
TM
: Theoretical Framework
N = Nc Ncrit
Ncrit
donde D en ft y N en rpm.
Moly-Cop Tools
TM
: Theoretical Framework
ECUACION DE LA POTENCIA
Pnet = c W sin N
Torque
with :
W sin
sin
= rap J (pD2/4) L
TM
: Theoretical Framework
Conventional
SAG
0.0400
(kWh/ton)/rev
J = 26 %
= 40
0.0300
0.0200
J = 38 %
= 32
0.0100
0.0000
0
10
15
20
25
30
35
40
45
8000 *(1 f v )
a
R
dB
Se ha demostrado que la variable nica y controlante del
efecto de la carga de bolas sobre los parmetros cinticos
es su rea especfica a, definida como la superficie
expuesta al impacto (m2) por unidad de volumen aparente
de carga (m3)
Moly-Cop Tools
TM
: Theoretical Framework
100
80
2
3
60
40
5
Current Technology Limit
6
8
20
Conventional Grinding
SAG Grinding
0
1
10
100
TM
Angle degrees
Charge Level, %
Molino 1
12.00
60
50
7.32
154.66
36.15
% Filling
Remarks :
40
30
20
10
0
0.50
0.60
0.70
0.80
h/D Ratio
0.90
1.00
TM
Remarks
Molino 1.
Mill
Power, kW
804
Lift
0
Angle, ()
129
36.00
933
10.00
1036
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
Mill
Power, kW
831
Lift
0
Angle, ()
133
36.00
965
10.00
1072
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
Balls
Interstitial
Filling,% Slurry Filling,%
36.00
100.00
Charge
Volume,
m3
17.91
72.00
2.80
1.86
7.75
Balls
Interstitial
Filling,% Slurry Filling,%
40.00
100.00
Charge
Volume,
m3
19.89
72.00
2.80
1.86
7.75
TM
Molino 1.
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Total Plant Throughput, ton/hr
13.03
9795
150.0
100.00
Length
ft
15.50
L/D
1.29
Mill Speed
% Critical
72.00
rpm
15.92
72.00
2.80
1.86
7.75
Charge
Filling,%
36.00
Balls
Interstitial
Filling,% Slurry Filling,%
36.00
100.00
Charge
Volume,
m3
17.91
Lift
Angle, ()
36.00
9.33
933
1
933
Mill
Power, kW
804
0
129
933
10.0
1036
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
TM
Molino 1.
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Total Plant Throughput, ton/hr
13.03
9795
150.0
103.43
Length
ft
15.50
L/D
1.29
Mill Speed
% Critical
72.00
rpm
15.92
72.00
2.80
1.86
7.75
Charge
Filling,%
40.00
Balls
Interstitial
Filling,% Slurry Filling,%
40.00
100.00
Charge
Volume,
m3
19.89
Lift
Angle, ()
36.00
9.33
965
1
965
Mill
Power, kW
831
0
133
965
10.0
1072
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
Las Odiosas
Limitantes Operacionales
Mandamiento #1
Debemos cuidar de no exceder la
potencia mxima del motor.
Adems, es
es preciso reconocer que, por
su geometra y diseo, no todos los
molinos industriales aceptan los mismos
niveles mximos de llenado.
llenado. En particular,
particular,
los del tipo overflow, de gran dimetro,
normalmente limitados a llenados
inferiores al 40%.
En general, niveles superiores al 42% de
llenado slo incrementan los consumos
de bolas, sin lograr a cambio un
correspondiente incremento en la tasa de
tratamiento.
TM
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Total Plant Throughput, ton/hr
13.03
9795
150.0
109.18
Length
ft
15.50
L/D
1.29
Mill Speed
% Critical
76.00
rpm
16.81
72.00
2.80
1.86
7.75
Charge
Filling,%
40.00
Balls
Interstitial
Filling,% Slurry Filling,%
40.00
100.00
Charge
Volume,
m3
19.89
Lift
Angle, ()
36.00
9.33
1018
1
1018
Mill
Power, kW
878
0
141
1018
10.0
1131
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
Las Odiosas
Limitantes Operacionales
Mandamiento #2
Debemos cuidar de no exceder la
potencia mxima del motor.
Aumentan los riesgos de impactos bola /
revestimientos
revestimiento
s y los resultantes daos a
estos ltimos, afectando negativamente la
disponibilidad operacional del equipo.
En el extremo, la carga de bolas puede
llegar a impactar preferentemente a las
barras levantadoras del extremo opuesto,
imperando una condicin de volante de
inercia, caracterizada por una
disminucin de la potencia demandada.
TM
Molino 1.
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Total Plant Throughput, ton/hr
13.03
7000
150.0
106.18
Length
ft
15.50
L/D
1.29
Mill Speed
% Critical
72.00
rpm
15.92
72.00
2.80
1.86
7.75
Charge
Filling,%
40.00
Balls
Interstitial
Filling,% Slurry Filling,%
40.00
100.00
Charge
Volume,
m3
19.89
Lift
Angle, ()
36.00
9.08
965
1
965
Mill
Power, kW
831
0
133
965
10.0
1072
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
Las Odiosas
Limitantes Operacionales
Mandamiento #3
Debemos disponer de capacidad ociosa
en la etapa previa de chancado.
La tecnologa actual permite chancar a
tamaos tan finos como 1/4, pero
difcilmente menores.
TM
Molino 1.
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Total Plant Throughput, ton/hr
13.03
7000
170.0
114.30
Length
ft
15.50
L/D
1.29
Mill Speed
% Critical
72.00
rpm
15.92
72.00
2.80
1.86
7.75
Charge
Filling,%
40.00
Balls
Interstitial
Filling,% Slurry Filling,%
40.00
100.00
Charge
Volume,
m3
19.89
Lift
Angle, ()
36.00
8.44
965
1
965
Mill
Power, kW
831
0
133
965
10.0
1072
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
Las Odiosas
Limitantes Operacionales
Mandamiento #4
Debemos analizar los posibles impactos
sobre la eficiencia de las etapas
siguientes en la cadena de procesamiento.
TM
Molino 1.
12.00
15.50
72.00
4.65
40.00
0.50
Eff. Diameter, m
Eff. Length, m
Mill Speed, rpm
Mill Volume, m3
Charge Weight, tons
3.66
4.73
15.92
49.74
92.43
Ore Properties :
Ore Density
ton/m3
2.80
Work Index
kWh/ton (metric)
13.03
2.77
67.80
2.35
79.83
Moly-Cop Tools TM
Planilla
Media Charge_
Optimal Ball Size ...
(Mixed Strings)
Molino 1.
12.00
15.50
72.00
4.65
40.00
0.50
Eff. Diameter, m
Eff. Length, m
Mill Speed, rpm
Mill Volume, m 3
Charge Weight, tons
Balanced Charge :
Top Size, in
Specific Area, m2/m3
Recharge Policy, %
Mill Charge Content, %
String 1
2.50
75.11
100.00
100.00
Ball Size, in
2.5
2.0
1.5
1.0
0.5
0.5
0.5
0.5
% Passing
100.00
40.87
12.82
2.40
0.00
0.00
0.00
0.00
% Passing
100.00
100.00
31.37
5.88
0.00
0.00
0.00
0.00
92.43
19.89
1494
3087
0.00
0.00
0
5666
Weight, tons
Volume, m3 (app)
Area, m2
# Balls per ton
String 2
2.00
93.38
0.00
0.00
Excess Area
3.66
4.73
15.92
49.74
92.43
Overall
Charge Area
Current Mix
75.11
Target Value
67.80
7.31
Balanced Charge,
% Retained
36.06
41.03
17.31
5.13
0.48
0.00
0.00
0.00
92.43
19.89
1494
3087
TM
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Total Plant Throughput, ton/hr
12.12
7000
170.0
122.92
Length
ft
15.50
L/D
1.29
Mill Speed
% Critical
72.00
rpm
15.92
72.00
2.80
1.86
7.75
Charge
Filling,%
40.00
Balls
Interstitial
Filling,% Slurry Filling,%
40.00
100.00
Charge
Volume,
m3
19.89
Lift
Angle, ()
36.00
7.85
965
1
965
Mill
Power, kW
831
0
133
965
10.0
1072
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Design Throughput, ton/hr
12.12
7000
170.0
500.00
Length
ft
21.00
L/D
1.20
Mill Speed
% Critical
72.00
rpm
13.18
Charge
Filling,%
38.00
72.00
2.80
1.86
7.75
Balls
Interstitial
Filling,% Slurry Filling,%
38.00
100.00
Charge
Volume,
m3
54.46
Lift
Angle, ()
35.00
(18)
Feed
% Solids
62.00
Circulating
Load, %
250.0
ton/hr
per Cyclone
437.5
Power, kW
2782 Balls
0 Overfilling
be set to any
445May
Slurry
3227desired
Net Total
value,
10.0 % Losses
using Tools / Goal
3586 Gross Total
Seek, changing
CellApparent
C19 or Cell
Density
D21..
D21
Power Oversize, %
# Cyclones
per Mill
4
7.85
3923
1
3923
m3/hr
per Cyclone
424.4
Pressure
Loss, psi
17.93
ton/m3
5.395
GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Design Throughput, ton/hr
12.12
7000
170.0
500.00
Length
ft
22.21
L/D
1.20
Mill Speed
% Critical
72.00
rpm
12.82
Charge
Filling,%
38.00
72.00
2.80
1.86
7.75
Balls
Interstitial
Filling,% Slurry Filling,%
38.00
100.00
Charge
Volume,
m3
64.39
Lift
Angle, ()
35.00
(0)
Feed
% Solids
62.00
Circulating
Load, %
250.0
ton/hr
per Cyclone
291.7
Power, kW
3382
0
542
3923
10.0
4359
Power Oversize, %
# Cyclones
per Mill
6
7.85
3923
1
3923
m3/hr
per Cyclone
282.9
Pressure
Loss, psi
7.64
Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total
Apparent
Density
ton/m3
5.395
La Ley de Bond
Es suficiente??
P80 = 150 mm
Distribucin de producto
Vortex ?
# of Cyclones ?
Carga
Circulante
Apex ?
170 tph
F80 = 10500 mm
Water ?
1833 kW
Moly-Cop Tools
TM
: Theoretical Framework
Configuraciones Tpicas
CIRCUITO DIRECTO
Overflow
7
5
Cyclone
Feed
Underflow
6
1
Fresh Feed
Water
Moly-Cop Tools
TM
: Theoretical Framework
Configuraciones Tpicas
CIRCUITO INVERSO
Overflow
7
5
Fresh
Feed
Water
Underflow
Cyclone
Feed
5
Moly-Cop Tools
TM
: Theoretical Framework
El Proceso de Clasificacin
Se denomina
Moly-Cop Tools
TM
: Theoretical Framework
Eficiencia de Clasificacin,
se denomina como la
fraccin de tamao en la
alimentacin
que
es
recuperada en la descarga.
Se espera que alcance su
mas alto valor para las
partculas gruesas en la
alimentacin y que el
contenido de partculas
finas sea mnimo
Moly-Cop Tools
TM
: Theoretical Framework
Moly-Cop Tools
TM
: Theoretical Framework
CARGA CIRCULANTE
Oflow
Moly-Cop Tools
TM
: Theoretical Framework
Moly-Cop Tools
TM
: Theoretical Framework
c
=
+
(1
)
E i B pw
B pw E i
c
E i = 1 - exp [-0.693.(
d 50 = a 2 *
DC
0.46
d 50 c
2
m
) ]
Dc * h 0.15
m = 1 exp [ a4 - 1.58 * Rv ] * [
]
Q
B pw =
Rv - . Rsc
1 - * Rsc
n
3.31
2
2 0.36
0.54
h *(DU/DO ) *(DU DO )
S = = a3 *
1.11
0.24
Qo
H . DC
Qu
Moly-Cop Tools
di
TM
Rv =
: Theoretical Framework
S
S +1
.exp(-7.63. .+10.79. 2
H = a1 *
0.20 0.15
0.51
1.65
0.53
DC .h . DI . DO . DU
1.46
c
E i = 1 - exp [-0.693.(
di
d 50
2
B pf = . B pw
B pw =
2
2.64
0.19
Qu
h .(DU / DO ) .exp(-4.33. +8.77. )
S = = a3 *
0.54
0.38
Qo
H . DC
Rv - . R sc
1 - .[1 - .(1 - R sc )]
Rv =
S
S +1
n
m
) ]
Dc .h
m = exp [ a 4 - 1.58. Rv ].[
]0.15
Q
Moly-Cop Tools
: Theoretical Framework
INTERACCIONES MOLIENDAMOLIENDA-CLASIFICACION
Moly-Cop Tools
TM
: Theoretical Framework
del proceso de
Molienda, se requiere que el contenido de particulas finas en el
molino sea lo mas baja posible............para una tarea de
molienda dada
Moly-Cop Tools
TM
: Theoretical Framework
0.28
0.26
F3 =
0.24
0.22
(1/fs7 - 1) + CL (1/fs6 - 1)
F7
% Solids
Underflow
(1 + CL)
72
0.20
0.18
0.16
CL
76
80
72
76
80
0.14
0.12
0.10
30
32
34
36
38
40
42
% Solids Overflow
Moly-Cop Tools
TM
: Theoretical Framework
44
46
48
Mass Balance
BallBal_Direct
P80 = 168 mm
Vortex= 9.1
# of Cyclones= 6
Apex 4.5
Circulating
Load 279
504 tph
F80 = 6912 mm
Water
4316 kW
Moly-Cop Tools
TM
: Theoretical Framework
BallBal_Direct
Theoretical Framework
BATCH PROCEDURE
Condiciones Iniciales
Molino 16 x 20
Nc : 38%
Vc : 73%
Hp : 2600
Bolas 3.5:2,5 (75:25)
Ciclones D26 (5)
Tm/hr : 290
CC : 360%
D50 : 190 micrones
By pass : 23%
Moly-Cop Tools
TM
: Theoretical Framework
TM
: Theoretical Framework
Metodologa de experimentacin
Condiciones de Molienda
Variable
Unidad
Valor
Tamao de Alimentacin
(% -1/2)
83
% de slidos
75
38
Llenado intersticial
40
Rpm
50
73
Tiempos de molienda
Min
2,4
Alimentacin a molino
Kg
7.5
Carga de bolas
Kg
21.0
Moly-Cop Tools
TM
: Theoretical Framework
Metodologa de experimentacin
Condiciones de Molienda
Monofraccin
Collar Evaluado
Tiempo de Mol.
+ 3/8"
3.5", 3.0"
2 y 4 min
-3/8", + 6"
3.5", 3.0",2.5'
"
-6, + 20
2.0", 2.5"
"
Alimentacin
Collar Evaluado
Area
Superficial
m2/m3
Representativa
3.5"
49.0
2 y 4 min
"
3.0"
58.0
"
"
2.5"
70.0
"
"
2.0"
86.0
"
Moly-Cop Tools
TM
: Theoretical Framework
Tiempo de
Molienda
Theoretical Framework
f1
2
S1Dt f1
2
b21S1Dt f1
f2
3
(1-S2Dt) f2
S2Dt f2
fi
bi1S1Dt f1
bi2S2Dt f2
i+1
i+1
bn1S1Dt f1
fn
t = t + Dt
bn2S2Dt f2
n+1
Moly-Cop Tools
TM
: Theoretical Framework
n+1
(2 - 1)
0.1
1
0.01
dcrit
0.001
1
10
100
1000
10000
Particle Size, mm
Moly-Cop Tools
TM
: Theoretical Framework
100000
100
Fraction 10x14 #
Fraction 14x20 #
Bij
Fraction 20x28 #
10
b0
b1
1
0.01
0.1
TM
: Theoretical Framework
Parmetros Caractersticos
EL CICLO OPTIMIZANTE
Nuevos
Proyectos
Instalaciones
Existentes
Pruebas Piloto
o de Laboratorio
Muestreo en
Planta
Nuevas Cond.
De operacin
Balance
De Materiales
Estimation
De Parametros
Escalamiento y
Simulacin
BallBal
SAGBal
BallParam
SAGParam
BallSim
SAGSim
Implementacion
Moly-Cop Tools
TM
Recomendaciones
: Theoretical Framework
TM
: Theoretical Framework
Mass Balance
BallParam_Direct
Moly-Cop Tools
TM
Remarks
Simulation N
psi
7.98
# of Cyclones
Vortex
Apex
10
7.50
3.67
% Solids
76.00
ton/hr
F80
400.0
9795
kWh/ton (Gross)
Wio (metric)
40.00 % Solids
59.97 % - Size 18
151.0 P80
0.382 Bpf
0.392 Bpw
Water,
m3/hr
10.79
15.14
Circ. Load
m3/hr
305.79
1542
Water,
m3/hr
356.9
% Solids
62.20
222.1
Gross kW
% Balls
% Critical
% Solids
Moly-Cop Tools
TM
4316.1
38.00
72.00
72.00
: Theoretical Framework
TM
DIRECT
Remarks
Sample N
Balls
Filling,%
38.00
Interstitial
Slurry Filling,%
100.00
Apex
3.67
Lift
Angle, ()
49.1
3348
0
536
3885
10.0
4316
Balls
Overfilling
Slurry
Net Power
% Losses
Gross kW
Charge
Volume,
m3
52.03
psi
7.98
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
ton/hr
Mill Discharge
% Retained % Passing
0.00
13.70
31.27
30.72
27.89
29.04
33.26
38.60
50.48
59.41
75.83
92.60
107.11
108.25
94.67
74.59
55.21
40.69
29.38
230.45
1223.14
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
6.10
4.51
3.33
2.40
18.84
100.00
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
0.00
72.00
1.862
1.000
ton/hr
Cyclone Feed
% Retained % Passing
0.00
18.18
41.50
40.76
37.01
38.54
44.14
51.22
66.99
78.84
100.62
122.88
142.13
143.65
125.63
98.98
73.26
54.00
38.99
305.81
1623.14
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
6.10
4.51
3.33
2.40
18.84
100.00
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
0.00
62.20
1.666
1.000
ton/hr
Cyclone U'flow
% Retained % Passing
0.00
18.18
41.50
40.77
37.02
38.54
44.15
51.22
66.99
78.85
100.53
120.95
131.23
116.42
85.81
56.91
36.45
24.14
16.24
117.25
1223.14
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
4.65
2.98
1.97
1.33
9.59
100.00
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
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
0.00
0.10
1.94
10.90
27.23
39.81
42.06
36.81
29.86
22.75
188.54
400.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.02
0.49
2.73
6.81
9.95
10.52
9.20
7.46
5.69
47.13
100.00
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
0.00
40.00
1.346
1.000
Moly-Cop Tools
BallParam_Direct : SIMULTANEOUS MASS BALANCE CLOSURE AND GRINDING PARAMETERS ESTIMATION
1
100
Weighting Factors :
Streams :
Mill Discharge
Cyclone U'flow
Cyclone O'flow
1
1
1
Size Distributions
% Solids
1
1
% Passing
Sample N
10
beta0
beta1
beta2
0.200
0.249
4.02
beta01
0
0 Default Value
Mill Discharge
Cyclone U'flow
Cyclone O'flow
Fresh Feed
3.058
Obj. Function :
0.011
Delta
1
10
100
1000
10000
0.062
Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
BallParam_Direct
Moly-Cop Tools
Planilla
BallParam_Direct
... (Reports)
TM
Simulation N
BALLPARAM_ DIRECT
Conventional Closed Circuit Grinding Simulator
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
95.00
Mill
Mill
Feed
Discharge
1598.5
1598.5
399.6
621.6
1998.0
2220.1
970.4
1192.5
2.059
1.862
58.8
47.9
80.00
72.00
Sump
Water
0.0
356.9
356.9
356.9
1.000
0.0
0.00
Cyclone
Feed
1598.5
971.3
2569.8
1542.2
1.666
37.0
62.20
Cyclone
U'flow
1198.5
378.5
1577.0
806.5
1.955
53.1
76.00
Cyclone
O'flow
400.0
600.0
1000.0
742.9
1.346
19.2
40.00
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
97.70
91.21
85.37
80.66
76.33
72.01
67.59
62.26
56.47
49.39
41.13
32.27
24.39
18.50
14.51
11.87
10.05
8.80
100.00
100.00
98.95
96.61
94.30
92.17
89.93
87.32
84.26
80.20
75.38
69.18
61.56
52.68
43.62
35.68
29.43
24.83
21.44
19.01
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
98.95
96.61
94.30
92.17
89.93
87.32
84.26
80.20
75.38
69.18
61.56
52.68
43.62
35.68
29.43
24.83
21.44
19.01
100.00
100.00
98.60
95.48
92.39
89.56
86.57
83.09
79.00
73.60
67.16
58.91
48.90
37.94
28.17
20.95
16.16
13.10
11.06
9.69
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.99
99.99
99.97
99.52
96.82
89.94
79.82
69.19
59.97
52.55
46.92
9795
4510
1164
1164
1844
151.0
10.79
15.14
kWh/ton (Gross)
kWh/ton (metric)
Moly-Cop Tools
Planilla
BallParam_Direct
... (Reports)
TM
Simulation N
BALLPARAM_ DIRECT
Conventional Closed Circuit Grinding Simulator
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
3.67
2.80
1542.2
7.98
183.2
39.2
38.2
1.66
305.8
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
98.60
95.48
92.39
89.56
86.57
83.09
79.00
73.60
67.16
58.91
48.90
37.94
28.17
20.95
16.16
13.10
11.06
9.69
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.99
99.99
99.97
99.52
96.82
89.94
79.82
69.19
59.97
52.55
46.92
1598.5
971.3
2569.8
1542.2
1.666
37.0
62.2
1198.5
378.5
1577.0
806.5
1.955
53.1
76.0
400.0
600.0
1000.0
742.9
1.346
19.2
40.0
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
0.985
0.924
0.810
0.681
0.574
0.499
0.451
0.422
0.382
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.999
0.976
0.877
0.692
0.484
0.311
0.189
0.111
0.065
0.016
Classifier Constants
a1
a2
a3
a4
9.677
1.428
54.957
0.549
0.976
Moly-Cop Tools
TM
Simulation N
BALLPARAM_ DIRECT
Planilla
BallParam_Direct
... (Reports)
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
Mid-Size
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
D80, microns
alpha01
0.00910
16.0
24.0
72.0
5.39
38.0
38.0
49.1
4316
3885
1598.5
72.0
2.70
3.87
Size Distributions
Mill
Mill
Feed
Discharge
100.00
100.00
97.70
91.21
85.37
80.66
76.33
72.01
67.59
62.26
56.47
49.39
41.13
32.27
24.39
18.50
14.51
11.87
10.05
8.80
100.00
100.00
98.95
96.61
94.30
92.17
89.93
87.32
84.26
80.20
75.38
69.18
61.56
52.68
43.62
35.68
29.43
24.83
21.44
19.01
4510
1164
Dcrit
6514
Theoretical Framework
SIMULACION DE CIRCUITOS DE
MOLIENDA / CLASIFICACION
Datos Operacionales
CYCLONES :
max. 10
P80 :
Psi :
< 13
CLASSIFIERS :
% Sol. :
F80 :
< 0.18 mm
6 Cyclones @ 26
< 80
POWER :
> 4.8 mm
< 4500 KW
WATER :
Feed :
PUMP :
MILL :
Moly-Cop Tools
TM
: Theoretical Framework
Moly-Cop Tools
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
Opening
Mid-Size
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0
Classifier Constants :
a1
a2
7.596
1.109
9.932
1.361
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
28.06
12.50
20.80
43.13
67.01
56.20
55.98
29.14
24.66
22.35
10.38
17.67
14.52
10.82
11.24
8.39
7.45
6.68
7.74
49.28
100.00
94.43
91.95
87.83
79.27
65.97
54.82
43.71
37.93
33.04
28.60
26.54
23.04
20.16
18.01
15.78
14.12
12.64
11.31
9.78
0.00
Expanded Form :
alpha02
alpha12
0
1
0
1 Suggested Default Values
dcrit
7093
Expanded Form :
beta01
0
0 Suggested Default Value
a3
53.836
52.968
5.57
2.48
4.13
8.56
13.30
11.15
11.11
5.78
4.89
4.43
2.06
3.51
2.88
2.15
2.23
1.66
1.48
1.32
1.54
9.78
a4
0.324
0.441
0.931
0.950
Planilla
BallSim_Direct
... (Reports)
Mill
Feed
504.0
26.5
530.5
206.5
2.569
87.2
95.00
Mill
Feed
Discharge
1902.5
1902.5
477.9
739.8
2380.3
2642.3
1157.3
1419.3
2.057
1.862
58.7
47.9
79.92
72.00
Sump
Cyclone
Water
0.0
464.4
464.4
464.4
1.000
0.0
0.00
Feed
1902.5
1204.2
3106.7
1883.7
1.649
36.1
61.24
Cyclone
U'flow
1398.5
451.4
1849.8
950.8
1.946
52.5
75.60
Cyclone
O'flow
504.0
752.9
1256.9
932.9
1.347
19.3
40.10
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
94.43
91.95
87.83
79.27
65.97
54.82
43.71
37.93
33.04
28.60
26.54
23.04
20.16
18.01
15.78
14.12
12.64
11.31
9.78
100.00
96.49
94.64
92.59
89.05
83.83
78.85
73.24
68.67
63.34
57.27
50.71
42.43
33.87
26.34
20.24
15.83
12.66
10.33
8.47
100.00
97.96
96.77
95.81
94.54
92.84
90.82
88.15
85.11
81.08
76.18
70.11
62.43
53.57
44.60
36.32
29.38
23.82
19.41
15.90
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
97.96
96.77
95.81
94.54
92.84
90.82
88.15
85.11
81.08
76.18
70.11
62.43
53.57
44.60
36.32
29.38
23.82
19.41
15.90
100.00
97.23
95.61
94.30
92.57
90.26
87.51
83.88
79.75
74.26
67.60
59.42
49.42
38.81
29.35
21.85
16.45
12.67
9.98
8.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.78
98.52
94.53
86.92
76.48
65.27
54.76
45.57
37.80
6913
3638
1099
1099
1735
169.4
Planilla
BallSim_Direct
... (Reports)
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
78.00
6.50
9.10
4.51
2.80
1883.7
7.7
183.3
37.5
34.9
1.34
277
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
Feed
U'flow
O'flow
100.00
97.96
96.77
95.81
94.54
92.84
90.82
88.15
85.11
81.08
76.18
70.11
62.43
53.57
44.60
36.32
29.38
23.82
19.41
15.90
100.00
97.23
95.61
94.30
92.57
90.26
87.51
83.88
79.75
74.26
67.60
59.42
49.42
38.81
29.35
21.85
16.45
12.67
9.98
8.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
99.99
99.78
98.52
94.53
86.92
76.48
65.27
54.76
45.57
37.80
1902.5
1204.2
3106.7
1883.7
1.649
36.1
61.2
1398.5
451.4
1849.8
950.8
1.946
52.5
75.6
504.0
752.9
1256.9
932.9
1.347
19.3
40.1
Classifier Efficiency
Actual
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.999
0.991
0.956
0.881
0.775
0.666
0.572
0.500
0.448
0.414
0.370
Corrected
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.999
0.986
0.933
0.817
0.655
0.487
0.342
0.231
0.152
0.099
0.032
Classifier Constants
a1
a2
a3
a4
7.596
1.109
53.836
0.324
0.931
TM
Remarks
Simulation N
Simulacin Molino 2.
psi
7.65
40.10 % Solids
54.76 % - Size 18
169.4 P80
# of Cyclones
Vortex
Apex
6
9.10
4.51
Circ. Load
m3/hr
% Solids
75.60
ton/hr
F80
504.0
6913
kWh/ton
Wio
0.349 Bpf
0.375 Bpw
Water,
m3/hr
8.56
13.21
2.77
1884
Water,
m3/hr
464.4
% Solids
61.24
262.0
Gross kW
% Balls
% Critical
% Solids
4316.1
38.00
72.00
72.00
Process Optimization
SiE, ton/kWh .
8 x 10 #
4x6#
14 x 20 #
28 x 35 #
3.0" String
2.5" String
2.0" String
0.1
100
1000
Particle Size, mm
Moly-Cop Tools
TM
: Theoretical Framework
10000
0.01
40
50
60
70
80
Moly-Cop Tools
TM
: Theoretical Framework
90
100
dcrit
Series A
Series B
Series C
Series D
1
40
50
60
70
80
Moly-Cop Tools
TM
: Theoretical Framework
90
100
dcrit / 10
0.1
0.01
40
50
60
70
80
TM
: Theoretical Framework
90
100
140
130
F80 = 9.8 mm
ton/hr
120
110
100
90
80
70
60
20
40
60
80
100
Moly-Cop Tools
TM
: Theoretical Framework
120
140
5.0 mm
160
ton/hr
9.8 mm
16.0 mm
140
20.0 mm
120
100
80
60
40
20
40
60
80
100
2
120
3
TM
: Theoretical Framework
140
100
80
2
3
60
40
5
6
20
Conventional Grinding
SAG Grinding
0
1
10
TM
: Theoretical Framework
100
SiE, ton/kWh
8 x 10 #
4x6#
14 x 20 #
28 x 35 #
3.0" String
2.5" String
2.0" String
0.1
100
1000
Particle Size, mm
Moly-Cop Tools
TM
: Theoretical Framework
10000
TM
: Theoretical Framework
Recarga Multiple
SiE, ton/kWh
1.00
0.10
Specific
Charge Area
54 m2/m3
67 m2/m3
0.01
0.01
0.1
Particle Size, mm
Moly-Cop Tools
TM
: Theoretical Framework
10
100
Recharge
100 %
100%
Policy
75 mm
64 mm
63
76
94
108
126
0.01128
0.01225
0.01273
0.01290
5079
3853
3370
3040
Area, m 2/m 3
7093
Current Condition
100%
50/50 %
100%
50 mm 50/38 mm 38 mm
220
200
180
160
140
3.0
120
2.5
2.0
1.5
100
50
60
70
80
90
100
110
120
TM
: Theoretical Framework
130
140
GRACIAS