About the Cyclosim_Single Spreadsheet ...

Scope : The Cyclosim_Single spreadsheet was designed to simulate the response of a hydrocyclone (or cluster of hydrocyclones) of any given geometry, operating in open circuit under known inlet conditions. Theoretical Framework : The technical literature contains various Empirical Correlations, attempting to describe the response of a hydrocyclone in front of a given set of operating conditions. Examples of these formulations are the work of T. C. Rao and A. J. Lynch from Australia ("Modelling and Scale-up of Hydrocyclone Classifiers", XI Int. Min. Proc. Congress II, 1-25, 1975. Also in the book Mineral Crushing and Grinding Circuits, Elsevier, New York, 1977), the research of L. R. Plitt in the USA ("A Mathematical Model for the Hydrocyclone Classifier", CIM Bulletin, p.114, December 1976) and the correlations proposed by CIMM in Chile (as reported by L. Gutirrez and J. E. Seplveda, Dimensionamiento y Optimizacin de Plantas Concentradoras Mediante Tcnicas de Modelacin Matemtica, CIMM Special Publication, 1986). Being all very similar in nature, the latter has been incorporated to Cyclosim_Single. In all of the above formulations, the Partition or Classification Function of the cyclones (defined as the fractional weight recovery to the cyclone underflow of any given size fraction in the feed; badly called Classification Efficiency) is decomposed into two effects : a direct feed slurry short-circuit to the underflow and the ideal (or corrected) classification of a hypothetical cyclone with no short-circuit at all, in such a way that : Ei = Bpf + (1 - Bpf ) Eic where, Ei Eic Bpf = actual cyclone classification efficiency (fractional partition) for particles of size di. = corrected cyclone classification efficiency for particles of size di, excluding the feed slurry short circuit. = fraction of the feed slurry that short-circuits the cyclone directly to the underflow.

The CIMM Model - essentially a variation of Plitt's Model - consists of the following 5 empirical correlations derived back in 1983, from a fairly extensive experimental program under a wide range of cyclone geometries and operating conditions : Correlation 1 : Cyclone Feed Pressure H = a1 where, H Q = cyclone feed pressure, expressed in equivalent ft of feed slurry. = volumetric cyclone feedrate, m3/hr. = fraction of solids in the cyclone feed, by volume.
_______________________ _______________________

Q1.46 exp( -7.63

+ 10.79

(DC)0.20 h0.15 (DI)0.51 (DO)1.65 (DU)0.53

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DC h DI DO DU

= cyclone diameter, in. = cyclone free height, defined as the distance from the bottom of the vortex finder down to the top of the apex, in. = cyclone feed inlet diameter (circle area equivalent if the inlet is rectangular), in. = cyclone vortex finder diameter, in. = cyclone apex diameter, in.

and a1 is an application dependent constant to be determined from at least one set of actual plant data using Spreadsheets Cyclobal_Single or Ballbal_Direct or Ballbal_Reverse, depending on the available data. Correlation 2 : Corrected Cut Size, d50 c. The corrected cut size d50 c is defined as that particular particle size that would be split on a 50:50 weight ratio between the overflow and underflow streams, based on the corrected efficiency curve : d50 c = a2
________________________ _______________________

(DC)0.44 (DI)0.58 (DO)1.91 exp( 11.12 ) (DU)0.80 h0.37 Q0.44 (

- 1 )0.5

where a2 is also an application dependent constant to be determined in a similar fashion as a1. Correlation 3 : Flow Split. S =
u ___ ___

h0.19 (DU/DO)2.64 exp( -4.33 = a3

+ 8.77

Qo

H0.54 (DC)0.38

where the flow split S (also referred to as the "wet" circulating load) is the ratio of the underflow volumetric flowrate to the overflow flowrate of slurry. Again a3 is to be determined as a1 and a2. Correlation 4 : Corrected Classification Efficiency. Eic = 1 - exp [ - 0.693 (di/d50 c)m ] where the so called Plitt's Parameter m, has been correlated as follows, m = exp [ a4 - 1.58 S/(S+1) ] [ (DC)2 h / Q ]0.15 and a4 is to be determined as a1, a2 and a3. Correlation 5 : Slurry Short-Circuit. The CIMM model contributed a 5th correlation relating (and so differentiating) the fractional slurry by-pass to the underflow (Bpf ) with the water by-pass (Bpw ), through a direct proportionality expression : Bpf = Bpw

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where is the 5th application dependent constant, like the previous a1, a2, a3 and a4 and where the water by-pass Bpw may be obtained from : S/(S+1) - Rsc Bpw =
______________ ______________

1- [1-

( 1 Rsc)]

with Rsc - the hypothetical total underflow weight recovery of solids if the actual cyclone efficiency was to be the corrected efficiency - given by : n Rsc =

i=1

fi Eic

and fi represents the weight fraction of particles of size di in the cyclone feed stream. The computation algorithm involves the direct evaluation of the first 4 correlations for H, d50 c, S and m to calculate the corrected partition curve Eic for every particle size di. Then proceeds with the calculation of Rsc to obtain Bpf , Bpw and finally, the desired actual partition function Ei for every particle size di. After these preliminary steps, the computation of the detailed mass balance around the cyclones is fairly straight forward. Data Input : All data required by the model must be defined in each corresponding unprotected white background cell 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. Simulation 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.

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mulate the response of a hydrocyclone (or cluster of n circuit under known inlet conditions.

elations, attempting to describe the response of a hydrocyclone of these formulations are the work of T. C. Rao and A. J. Lynch e Classifiers", XI Int. Min. Proc. Congress II, 1-25, 1975. Also in the New York, 1977), the research of L. R. Plitt in the USA ("A M Bulletin, p.114, December 1976) and the correlations proposed Seplveda, Dimensionamiento y Optimizacin de Plantas emtica, CIMM Special Publication, 1986). Being all very similar in ngle.

ication Function of the cyclones (defined as the fractional weight ion in the feed; badly called Classification Efficiency) is circuit to the underflow and the ideal (or corrected) classification of a way that :

Bpf ) Eic

cy (fractional partition) for particles of size di. iency for particles of size di, excluding the feed slurry short

circuits the cyclone directly to the underflow.

del - consists of the following 5 empirical correlations derived back der a wide range of cyclone geometries and operating conditions :

+ 10.79

(DO)1.65 (DU)0.53

n equivalent ft of feed slurry.

d, by volume.

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distance from the bottom of the vortex finder down to the top

rea equivalent if the inlet is rectangular), in.

mined from at least one set of actual plant data using allbal_Reverse, depending on the available data.

article size that would be split on a 50:50 weight ratio between the d efficiency curve : exp( 11.12 )
s

- 1 )0.5

e determined in a similar fashion as a1.

6 4

exp( -4.33 (DC)0.38

+ 8.77

_______ ______

04 .5

lating load) is the ratio of the underflow volumetric flowrate to the as a1 and a2.

ated as follows,

(DC)2 h / Q ]0.15

and so differentiating) the fractional slurry by-pass to the underflow rtionality expression :

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the previous a1, a2, a3 and a4 and where the water by-pass Bpw

Rsc)]

y of solids if the actual cyclone efficiency was to be the corrected

in the cyclone feed stream.

n of the first 4 correlations for H, d50 c, S and m to calculate the en proceeds with the calculation of Rsc to obtain Bpf , Bpw and finally, size di. After these preliminary steps, the computation of the ght forward.

corresponding unprotected white background cell of the here contain the results of the corresponding formulas there defined

sheet.

ief comments inserted in each relevant cell, rendering the whole

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Moly-Cop Tools TM CYCLOSIM

# of Cyclones 10 Operating Conditions :

Diameter 20.00

Cyclones Geometry, inches Height Inlet Vortex 75.00 3.50 7.50 Ore Density, ton/m3

Apex 3.67 2.80

Dry Tons ton/hr 1622.84

Water m3/hr 986.16

Cyclone Feed Conditions Slurry Flow Density ton/hr m3/hr ton/m3 2609.01 1565.75 1.666

% Solids (by volume) 37.02

% Solids (by weight) 62.20

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse) a1 a2 a3 a4 9.680 1.401 54.964 0.523 0.950 9.680 1.401 54.964 0.523 0.950 Feed Size Distribution : 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 0.74 0.53 0.37 3 4 6 8 10 14 20 28 35 48 65 100 150 200 270 400 -400 Opening 25400 19050 12700 9500 6700 4750 3350 2360 1700 1180 850 600 425 300 212 150 106 75 53 38 0 Mid-Size 30206 21997 15554 10984 7978 5641 3989 2812 2003 1416 1001 714 505 357 252 178 126 89 63 45 19 Total ton/hr 0.00 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

Suggested Default Values

% Ret 0.00 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

% Pass 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

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Moly-Cop Tools TM CYCLOSIM

Sample N

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

10 20.00 75.00 3.50 7.50 3.67 2.80

Operating Conditions : Feed Flowrate, m3/hr Pressure, psi D50 (corr.), microns Water By-Pass, % Solids By-Pass, % Plitt's Parameter Circulating Load, % 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 77.82 72.34 65.89 57.67 47.79 37.06 27.54 20.52 15.87 12.89 10.92 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 89.95 80.00 69.49 60.28 52.82 47.13

1565.7 8.0 179.8 39.2 37.2 1.62 306

Mesh 1.05 0.74 0.53 0.37 3 4 6 8 10 14 20 28 35 48 65 100 150 200 270 400 -400

Opening 25400 19050 12700 9500 6700 4750 3350 2360 1700 1180 850 600 425 300 212 150 106 75 53 38 0

Mid-Size 30206 21997 15554 10984 7978 5641 3989 2812 2003 1416 1001 714 505 357 252 178 126 89 63 45 19

Classifier Efficiency Actual Corrected 1.000 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 0.810 0.683 0.575 0.498 0.447 0.417 0.383 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.998 0.975 0.878 0.698 0.495 0.323 0.200 0.119 0.071 0.018

D80, microns Ore, ton/hr Water, m3/hr Slurry, ton/hr Slurry, m3/hr Slurry Dens., ton/m3 % Solids (by volume) % Solids (by weight)

1273 1622.8 986.2 2609.0 1565.7 1.666 37.0 62.2

2022 1222.9 386.3 1609.2 823.0 1.955 53.1 76.0

150.0 399.9 599.9 999.8 742.7 1.346 19.2 40.0 Classifier Constants a1 a2 a3 a4 9.680 1.401 54.964 0.523 0.950

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Cyclones Geometry, inches Diameter 20.0 Operating Conditions : ton/m3 156.57

Height 75.0

Inlet 3.50

Vortex 7.50

Apex 3.67

(by volume) 0.370

s 2.80

ton/hr 162.28

m3/hr 98.62

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse) a1 a2 a3 a4 9.680 1.401 54.964 0.523 Calculations Correlation 1. Cyclone Feed Pressure, ft. H 11.06 Correlation 2. Corrected Cut Size, microns. d50c 179.81 Correlation 3. Slurry Split. S 1.11 Correlation 4. Classification Efficiency. m (Plitt) 1.62 Fraction # Rsc 0.61 Tyler Mesh Bpw 0.39 Opening micr. di* micr. Bpf 0.37 Feed ton Water U'flow 38.63 % Sol. 76 Ei % Ret. (corr) Water O'flow 59.99 Rsc,i = fi Eic

0.950

% Sol. 40 Ei (real) Underflow ton Overflow ton

% Ret.

% Ret.

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

1.05 0.74 0.53 0.37 3 4 6 8 10 14 20 28 35 48 65 100 150 200 270 400 -400 TOTAL

25400 19050 12700 9500 6700 4750 3350 2360 1700 1180 850 600 425 300 212 150 106 75 53 38 0

30206 21997 15554 10984 7978 5641 3989 2812 2003 1416 1001 714 505 357 252 178 126 89 63 45 19

0.00 0.00 1.82 4.15 4.08 3.70 3.85 4.41 5.12 6.70 7.88 10.06 12.29 14.21 14.36 12.56 9.90 7.32 5.40 3.90 30.58 162.28

0.00 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

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

0.000 0.000 0.011 0.026 0.025 0.023 0.024 0.027 0.032 0.041 0.049 0.062 0.074 0.077 0.062 0.038 0.020 0.009 0.004 0.002 0.003 0.608

1.000 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 0.810 0.683 0.575 0.498 0.447 0.417 0.383

0.00 0.00 1.82 4.15 4.08 3.70 3.85 4.41 5.12 6.70 7.88 10.05 12.09 13.12 11.64 8.58 5.69 3.64 2.41 1.62 11.73

0.00 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

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.19 1.09 2.72 3.98 4.21 3.68 2.99 2.27 18.85 39.99 3.06

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.03 0.49 2.73 6.81 9.95 10.52 9.20 7.46 5.69 47.13 100.00

122.29 Circulating Load :