Moly-Cop Tools, Version 3.

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 :

f i = [ wF (fiF - fiF)2 + wU (fiU - fiU)2 + wO(fiO - fiO)2 ] ,for every particle size d i

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 S [(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.

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 Moly-Cop Tools, Version 3.0
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 - l/wF

fiU U = fiU U + l/wU
fiO O = fiO O + l/wO ; for n = 1, n

with the Lagrange multiplier l given by :

l = ( 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.

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Moly-Cop Tools / 374860154.xlsx 12/19/2017 / 03:47:31
 Moly-Cop Tools TM
(Version 3.0)
Cyclobal_Single : HYDROCYLONE MASS BALANCE CLOSURE

Sample N 1
100
Weighting Factors :
Streams :
Cyclone Feed 1
Cyclone U'flow 1
Cyclone O'flow 1

% Passing
Size Distributions 1
% Solids 1

10

Initial Guesses :
Bpf Bpc d50c m
0.372 0.000 179.8 1.618 4

Obj. Function : 0.000 Cyclone Feed

Cyclone U'flow
Cyclone O'flow
Classifier Constants : Column E
Column F
a1 0.95 Column G
1
a2 1.029
10 100 1000 10000
a3 55.37
Particle Size, microns
a4 0.554
l 0.950

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 Moly-Cop Tools TM
(Version 3.0)
HYDROCYCLONE MASS BALANCE CLOSURE

Remarks Base Case Example Sample N 1

Cyclone Dimensions, inches Ore Density, ton/m3 2.80

Number Diameter Height Inlet Vortex Apex Dry Feedrate, ton/hr 2105.9
6 26.0 78.0 6.50 9.10 4.60 Volumetric Flow, m3/hr 2031.8
Default Values: 78.0 6.50 9.10 4.55 Cyclones Pressure, psi 8.00

EXPERIMENTAL SIZE DISTRIBUTIONS

Cyclone Feed Cyclone U'flow Cyclone O'flow
i Mesh Opening Mid-Size ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained
1 1.05 25400 100.00 100.00
2 0.742 19050 21997 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00
3 0.525 12700 15554 23.58 1.12 98.88 23.58 1.49 98.51 0.00 0.00
4 0.371 9500 10984 53.84 2.56 96.32 53.84 3.39 95.12 0.00 0.00
5 3 6700 7978 52.89 2.51 93.81 52.89 3.33 91.79 0.00 0.00
6 4 4750 5641 48.02 2.28 91.53 48.02 3.03 88.76 0.00 0.00
7 6 3350 3989 50.00 2.37 89.16 50.00 3.15 85.61 0.00 0.00
8 8 2360 2812 57.27 2.72 86.44 57.27 3.61 82.00 0.00 0.00
9 10 1700 2003 66.45 3.16 83.28 66.45 4.19 77.81 0.00 0.00
10 14 1180 1416 86.91 4.13 79.16 86.91 5.48 72.34 0.00 0.00
11 20 850 1001 102.29 4.86 74.30 102.29 6.45 65.89 0.00 0.00
12 28 600 714 130.55 6.20 68.10 130.42 8.22 57.67 0.13 0.02
13 35 425 505 159.43 7.57 60.53 156.91 9.89 47.78 2.52 0.49
14 48 300 357 184.40 8.76 51.77 170.25 10.73 37.05 14.15 2.73
15 65 212 252 186.37 8.85 42.92 151.04 9.52 27.54 35.33 6.81
16 100 150 178 162.99 7.74 35.18 111.33 7.02 20.52 51.66 9.95
17 150 106 126 128.42 6.10 29.08 73.84 4.65 15.87 54.58 10.52

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 18 200 75 89 95.05 4.51 24.57 47.28 2.98 12.89 47.77 9.20
19 270 53 63 70.06 3.33 21.24 31.32 1.97 10.91 38.74 7.46
20 400 38 45 50.58 2.40 18.84 21.06 1.33 9.59 29.52 5.69
21 -400 0 19 396.76 18.84 0.00 152.11 9.59 0.00 244.65 47.13
Totals 2105.85 100.00 1586.80 100.00 519.05 100.00

% Solids 62.20 76.00

Weighting Factor 1.000 1.000

Moly-Cop Tools / 374860154.xlsx 12/19/2017 / 03:47:31

 EXPERIMENTAL SIZE DISTRIBUTIONS
Cyclone O'flow
% Passing
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

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 60.29
52.82
47.13
0.00

40.00
1.000

Moly-Cop Tools / 374860154.xlsx 12/19/2017 / 03:47:31

 Moly-Cop Tools TM
(Version 3.0)

CYCLOBAL Sample N 1
Cyclone Mass Balance Closure

Remarks : Base Case Example

Number of Cyclones : 6 Operating Conditions :

Cyclone Dimensions, in : Feed Flowrate, m3/hr 2031.8
Diameter 26.00 Pressure, psi 8.0
Height 78.00 D50 (corr.), microns 179.8
Inlet 6.50 Water By-Pass, % 39.2
Vortex 9.10 Solids By-Pass, % 37.2
Apex 4.60 Plitt's Parameter 1.62
Ore Density, ton/m3 2.80 Circulating Load, % 306

Size Distributions, % Passing Classifier Efficiency

Mesh Opening Mid-Size Feed U'flow O'flow Actual Corrected

1.05 25400 21997 100.00 100.00 100.00 1.000 1.000

0.742 19050 15554 100.00 100.00 100.00 1.000 1.000
0.525 12700 10984 98.88 98.51 100.00 1.000 1.000
0.371 9500 7978 96.32 95.12 100.00 1.000 1.000
3 6700 5641 93.81 91.79 100.00 1.000 1.000
4 4750 3989 91.53 88.76 100.00 1.000 1.000
6 3350 2812 89.16 85.61 100.00 1.000 1.000
8 2360 2003 86.44 82.00 100.00 1.000 1.000
10 1700 1416 83.28 77.81 100.00 1.000 1.000
14 1180 1001 79.16 72.34 100.00 1.000 1.000
20 850 714 74.30 65.89 100.00 0.999 0.998
28 600 505 68.10 57.67 99.97 0.984 0.975
35 425 357 60.53 47.78 99.49 0.923 0.878
48 300 252 51.77 37.05 96.76 0.810 0.698
65 212 178 42.92 27.54 89.96 0.683 0.495
100 150 126 35.18 20.52 80.00 0.575 0.323
150 106 89 29.08 15.87 69.49 0.497 0.200
200 75 63 24.57 12.89 60.29 0.447 0.119
270 53 45 21.24 10.91 52.82 0.416 0.071
400 38 19 18.84 9.59 47.13 0.383 0.018

D80, microns 1273 2022 150.0

Ore, ton/hr 2105.9 1586.8 519.1 Classifier Constants

Water, m3/hr 1279.7 501.1 778.6 a1 7.096
Slurry, ton/hr 3385.5 2087.9 1297.6 a2 1.029
Slurry, m3/hr 2031.8 1067.8 964.0 a3 55.366

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 Slurry Dens., ton/m3 1.666 1.955 1.346 a4 0.554
% Solids (by volume) 37.0 53.1 19.2 l 0.950
% Solids (by weight) 62.2 76.0 40.0 Bpc 0.000

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 Moly-Cop Tools TM
(Version 3.0)

CYCLOBAL Sample N 1
Raw Experimental Data

Remarks : Base Case Example

Number of Cyclones : 6 Operating Conditions :

Cyclone Dimensions, in : Feed Flowrate, m3/hr 2031.8
Diameter 26.00 Pressure, psi 8.0
Height 78.00
Inlet 6.50
Vortex 9.10
Apex 4.60
Ore Density, ton/m3 2.80 Circulating Load, % 306

Size Distributions, % Passing

EXPERIMENTAL VALUES FITTED VALUES
Mesh Opening Mid-Size Feed U'flow O'flow Feed U'flow O'flow

1.05 25400 21997 100.00 100.00 100.00 100.00 100.00 100.00

0.742 19050 15554 100.00 100.00 100.00 100.00 100.00 100.00
0.525 12700 10984 98.88 98.51 100.00 98.88 98.51 100.00
0.371 9500 7978 96.32 95.12 100.00 96.32 95.12 100.00
3 6700 5641 93.81 91.79 100.00 93.81 91.79 100.00
4 4750 3989 91.53 88.76 100.00 91.53 88.76 100.00
6 3350 2812 89.16 85.61 100.00 89.16 85.61 100.00
8 2360 2003 86.44 82.00 100.00 86.44 82.00 100.00
10 1700 1416 83.28 77.81 100.00 83.28 77.81 100.00
14 1180 1001 79.16 72.34 100.00 79.16 72.34 100.00
20 850 714 74.30 65.89 100.00 74.30 65.89 100.00
28 600 505 68.10 57.67 99.97 68.10 57.67 99.97
35 425 357 60.53 47.78 99.49 60.53 47.78 99.49
48 300 252 51.77 37.05 96.76 51.77 37.05 96.76
65 212 178 42.92 27.54 89.96 42.92 27.54 89.96
100 150 126 35.18 20.52 80.00 35.18 20.52 80.00
150 106 89 29.08 15.87 69.49 29.08 15.87 69.49
200 75 63 24.57 12.89 60.29 24.57 12.89 60.29
270 53 45 21.24 10.91 52.82 21.24 10.91 52.82
400 38 19 18.84 9.59 47.13 18.84 9.59 47.13

Ore, ton/hr 2105.9 1586.8 519.1

Water, m3/hr 1279.7 501.1 778.6
Slurry, ton/hr 3385.5 2087.9 1297.6
Slurry, m3/hr 2031.8 1067.8 964.0
Slurry Dens., ton/m3 1.666 1.955 1.346
% Solids (by volume) 37.02 53.07 19.23

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 % Solids (by weight) 62.2 76.0 40.0

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 C

Number of Cyclones 6
Classifier Dimensions, inches.
DC h DI DO DU
26 78 6.5 9.1 4.6
Classifier Constants
a1 a2 a3 a4 l Cyclone Cyclone Cyclone
7.0964809 1.0287158 55.366094 0.5540901 0.95 Feed U'flow O'flow
Circulating Load, CL 3.0571111 Solids, tons 350.98 264.47 86.508599
Slurry Split, S 1.1077387 Water, m3/hr 213.28 83.52 129.76
Cyclone Pressure, ft 11.087895 Slurry, tons 564.25361 347.98211 216.2715
Cyclone Pressure, lb/in2 8.00 Slurry, m3/hr 338.62682 177.968 160.65883
Corrected Cut Size, d50c, microns 179.80906 Solids Density, ton/m3 2.8 2.8 2.8
Water By-Pass 0.3915803 Slurry Density, ton/m3 1.6662992 1.9553072 1.3461538
Fines By-Pass 0.3720013 % Solids (by volume) 37.016623 53.072625 19.230769
Coarse By-Pass 0 % Solids (by weight) 62.20 76.00 40.00
Plitt's Parameter 1.6175442
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 25400
2 19050 21997.045 1 0.00 0 0.00 0.00 0.00 0.00
3 12700 15554.26 1 23.58 23.580566 0.00 1.12 1.49 0.00
4 9500 10984.079 1 53.84 53.838693 0.00 2.56 3.39 0.00
5 6700 7978.095 1 52.89 52.88672 0.00 2.51 3.33 0.00
6 4750 5641.3651 1 48.02 48.020148 0.00 2.28 3.03 0.00
7 3350 3989.0475 1 50.00 50.000232 0.00 2.37 3.15 0.00
8 2360 2811.761 1 57.27 57.271249 0.00 2.72 3.61 0.00
9 1700 2002.9978 1 66.45 66.449169 0.00 3.16 4.19 0.00
10 1180 1416.3333 1 86.91 86.910265 0.00 4.13 5.48 0.00
11 850 1001.4989 0.9999909 102.29 102.28921 0.00 4.86 6.45 0.00
12 600 714.14284 0.999008 130.55 130.41925 0.13 6.20 8.22 0.02
13 425 504.97525 0.9841985 159.43 156.90861 2.52 7.57 9.89 0.49
14 300 357.07142 0.9232651 184.40 170.25039 14.15 8.76 10.73 2.73
15 212 252.1904 0.8104305 186.37 151.03816 35.33 8.85 9.52 6.81
16 150 178.32555 0.683044 162.99 111.32795 51.66 7.74 7.02 9.95

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17 106 126.0952 0.5749558 128.42 73.8358 54.58 6.10 4.65 10.52

18 75 89.162773 0.4974461 95.05 47.281531 47.77 4.51 2.98 9.20
19 53 63.047601 0.4470162 70.06 31.3183 38.74 3.33 1.97 7.46
20 38 44.877611 0.4164464 50.58 21.063644 29.52 2.40 1.33 5.69
21 0 19 0.3833753 396.76 152.10851 244.65 18.84 9.59 47.13

Total 2105.85 1586.80 519.05 100.00 100.00 100.00

Page 14
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% Passing (model) % Passing (exp) (Weighted Error)^2

Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone Cyclone
Feed U'flow O'flow Feed U'flow O'flow Feed U'flow O'flow
1 1 1
100.00 100.00 100.00 100.00 100.00 100.00
100.00 100.00 100.00 100.00 100.00 100.00 0.000 0.000 0.000
98.88 98.51 100.00 98.88 98.51 100.00 0.000 0.000 0.000
96.32 95.12 100.00 96.32 95.12 100.00 0.000 0.000 0.000
93.81 91.79 100.00 93.81 91.79 100.00 0.000 0.000 0.000
91.53 88.76 100.00 91.53 88.76 100.00 0.000 0.000 0.000
89.16 85.61 100.00 89.16 85.61 100.00 0.000 0.000 0.000
86.44 82.00 100.00 86.44 82.00 100.00 0.000 0.000 0.000
83.28 77.81 100.00 83.28 77.81 100.00 0.000 0.000 0.000
79.16 72.34 100.00 79.16 72.34 100.00 0.000 0.000 0.000
74.30 65.89 100.00 74.30 65.89 100.00 0.000 0.000 0.000
68.10 57.67 99.97 68.10 57.67 99.97 0.000 0.000 0.000
60.53 47.78 99.49 60.53 47.78 99.49 0.000 0.000 0.000
51.77 37.05 96.76 51.77 37.05 96.76 0.000 0.000 0.000
42.92 27.54 89.96 42.92 27.54 89.96 0.000 0.000 0.000
35.18 20.52 80.00 35.18 20.52 80.00 0.000 0.000 0.000

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29.08 15.87 69.49 29.08 15.87 69.49 0.000 0.000 0.000

24.57 12.89 60.29 24.57 12.89 60.29 0.000 0.000 0.000
21.24 10.91 52.82 21.24 10.91 52.82 0.000 0.000 0.000
18.84 9.59 47.13 18.84 9.59 47.13 0.000 0.000 0.000

Overall
0.000 0.000 0.000

Page 16