SIZING OF GRINDING EQUIPMENT
1.0.0 OBJECTIVE : Calculate the dimensions of the main equipment in the grinding stage.
2.0.0 CALCULATION BASIS
Regrinding capacity
Design : 8404.08 t/d
Ore characteristics
Specific gravity : 4.36
Work Index : 14.5 kWh/st
Feed size
F80 : 500 m
Product size
P80 : 80 m
Characteristic of the regrinding circuit
Type : closed-indirect
Circulating load : 250%
% solids
Discharge ball mill : 70%
Hydrocyclone feed : 55%
Hydrocyclone overflow : 35%
Hydrocyclone underflow : 70%
Mill operation
Discharge type : Overflow
% Mill load : 40%
% Critical speed : 75%
2.1.0 Primary mill
Capacidad de alimentacin en st/h
Feed capacity in st/h
The screens feed capacity to size will be 8404.08 t / d, and because it will operate 24 hours a
day, its capacity (t/h) will be:
Capacity (t/h) = = 376.52 t/h
And converting to short tons
Capacity (st/h) = 376.52 t/h x (1.1023 st/t) = 414.46 st/h
Once we have the feed capacity in (st/h), we will be proceed to calculate the Bond equations
factors with the purpose of sizing ball mill.
Calculating Bond factors
F1: Correction factor for dry milling. Does not apply.
F2: Correction factor for grinding in open circuit. Does not apply.
F3: Correction factor for mil diameter.
F3 =
For an initial diameter of 8 in, the correction factor will be:
F3 = 1
F4: Correction factor for feeding coarse size.
F4 = ; solo si F80 Fo
= 4000. ; = optimal feed size ( )
Applying the optimal feed size equation:
= 4000. = = 3787.46 m
being F80 < ,correction factor does not apply
F5: Correction factor for extra fineness of grind. A correction factor fineness of grind is applicable
When greater than 80% of the ground product is less than 74 in size. In our case (P80 =
80
m) the factor F5 is not applied.
F7: Correction factor for low reduction ratio, for ball mills. If the ball mill reduction ratio is less
than
6, a correction factor, F7, is not applied. In our case the reduction ratio ( = F80/P80 = 83.3)
is higher than 6.
Calculation of corrected Work index
xF3 = x(1.0)
Calculation of specific energy (W)
Calculation of mechanical power
=
= Mechanical power (HP)
= Specific energy (kWh/st)
=
Calculation of electrical power
= Electrical power (HP)
= x100/ = 5402.29 x100/95
= Efficiency (%)
= 5686.62 HP
Calculation of mill dimensions
5686.62 HP = 4.365x x x
D =16.41
L= 32.82
As D is different from 8, we will recalculate F3, repeating the previous steps according to table
N1.
Table 3.1
WI(corr) W PE D L
Factor F3 %Error
(kWh/st) (kWh/st) (HP) (ft) (ft)
1 14.5 9.72 5686.62 16.410 32.820
13.26 8.89 5201.03 16.001 32.003 -0.025
13.26 8.89 5201.03 16.001 32.003 0.00
After 3 iterations it is observed that the relative error of the diameter (D) will be: 0.025%.
Therefore the new dimensions of the mill will be:
D = 16.001 ft 16.5 ft
L = 32.003 ft 33 ft
Calculating the electrical power with the new dimensions:
= 4.365x x x
= 5790.6 HP
Finally choosing a 5800 hp motor.
Selecting the number of hydrocyclones
The volumetric capacity of a cyclone depends upon is diameter. Once the required diameter has
been defined then the number of units needed to handle the given feed flow can be determined
from
For a hydrocyclone of 121.78 mm diameter, the feed flow is 968.22 m3 / h.
N of hydroyiclones =
Pulp flowrate = T(t/h)x(1+ %CC/100)x( + )
Pulp flowrate = 376.52 t/h x (1+250/100)x( + )
Pulp flowrate = 1380.49m3/h
N of hydrocyclones = = 1.43
N of hydrocyclones = 2
2.2.0 Hydrocyclone
The application METSO method is shown for preliminary selection of hydrocyclone.
Calculation d50c
Table 2 lists the distribution of overflow sizes with the hydrocyclone d50c. In our case the feed
size required for cyanidation is 80% - 80 m.
Table 3.2
%Passing in overflow Factor
95 0.65
90 0.79
80 1.06
70 1.36
d50c = Factor x product size = 1.06 x 80 m
d50c = 84.8 m
Calculating the diameter of the hydrocyclone
Once d50c is defined, the hydrocyclone diameter can be selected from Table 3.3.
Table 3.3
For d50c = 84.8 m, the diameter of the hydrocyclone will be 500 mm (20 in).
Selecting the number of hydrocyclones
The volumetric capacity of a cyclone depends upon is diameter. Once the required diameter has
been defined then the number of units needed to handle the given feed flow can be determined
from Table 4.4.
Table 4.4
For a hydrocyclone of 500 mm diameter, the feed flow is 500 m3 / h.
N of hydroyiclones =
Pulp flowrate = T(t/h)x(1+ %CC/100)x( + )
Pulp flowrate = 376.52 t/h x (1+250/100)x( + )
Pulp flowrate = 1380.49m3/h
N of hydrocyclones = = 2.76
N of hydrocyclones = 3
3.0.0 CONCLUSION
The chosen equipment for grinding will be a mil of 16.5x33 metso motor of 5800HP.
The mill 16.5x33 will operate with three hydrocyclone of 17 in of diameter (1 stand by)
3.1.0 Hydrocyclone
The application Krebs Engenieers method is shown for preliminary selection of hydrocyclone.
Calculation d50c
Table 2 lists the distribution of overflow sizes with the hydrocyclone d50c. In our case the feed
size required for cyanidation is 80% - 80 m.
Table 3.2
%Passing in overflow Factor
95 0.73
90 0.91
80 1.25
70 1.67
D50C (APLICACIN) = Factor x product size = 1.25 x 80 m
D50C (APLICACIN) = 100 m
Calculating the diameter of the hydrocyclone
kreebs Engenieers method
D50(APLICACIN)= D50C(BASE)*C1*C2*C3
Donde
C1: Factor de porcentaje de solidos en volumen
C1= ((53-V)/53)-1.43
Donde = 19.31
Reemplazando
C1= 1.91
C2: Factor de correccin debido a la cada de presin a travs del ciclon
C2 = 3.27*(p^-0.28) p: presin en kpa
Dato
Considerando un presin de 7 psi (48.23 Kpa)
p =48.23 Kpa
C2= 1.10
C3: Factor de gravedad especifica de los solidos
C3= (1.65/(Gs-Gl))^0.5
Se tiene como datos Gs= 4.36
C3=0.7
Calculando el D50c(BASE)
D50(APLICACIN)= D50C(BASE)*C1*C2*C3
100 um= D50C(BASE)*1.91*1.10*0.7
D50C (BASE) = 67.58 um
Calculando el Dimetro del hidrocicln
D50C (BASE) =2.84*(D^0.66)
D=121.78 cm
CALCULO DE CAPACIDAD VOLUMETRICA DEL HIDROCICLONES
Q=0.7*(P^0.5)*D^2 Q=FLUJO DE PULPA ACEPTADO POR EL
HIDROCICLON EN USGPM
Q= 4263.4 USGPM
D=DIAMETRO INTERIOR DEL CICLON EN
Se sabe: 1GAL(US) = 3.785 LITRO PULGADAS
Q = 268.95 litros /seg P=INCREMENTO DE PRESION
Q= 968.22 m3/hora
4.0.0 CONCLUSION
The chosen equipment for grinding will be a mil of 16.5x33 motor of 5800HP.
The mill 16.5x33 will operate with two hydrocyclones of 48 in (121.9 cm) of diameter (1 stand
by).
%
SOLIDS % SOLIDS ST / Hr Gallons per minute DENSITY Kg/lit SOLIDS
CYCLONES PRODUCTS DST/Hr. WEIGHT PULP H2O H2O SOLIDS PULP PULP SOLIDS Cv %
Cyclones Underflow 965.0 75.74 1273.99 309.0 1236.05 779.78 2015.83 2.528 4.950 38.683
Cyclones Overflow 386.0 35.00 1102.84 716.8 2867.37 354.12 3221.49 1.369 4.360 10.992
Cyclones Feed 1351.0 56.84 2376.83 1025.9 4103.42 1133.90 5237.32 1.815 4.766 21.650
PRESION
FLUJO
DIAM FACTOR DE CORRECCION POR PRSION POR NUMERO DE
ALIM CYCLONE D50 CONDICIONES D50 ALIM CICLON CYCLONES
BASE EFECTIVO GPM
Kpa PULG um C1 C2 C3 um PSI CAP NETO TOTAL
HIDROCICLONES DE 30 PULGADAS DIAMETRO
280.00 30 49.59 2.233 0.675 0.662 49.48 40.61 4055.53 1.29 2.00
260.00 30 49.59 2.233 0.689 0.662 50.52 37.71 3908.00 1.34 2.00
240.00 30 49.59 2.233 0.705 0.662 51.67 34.81 3754.69 1.39 2.00
200.00 30 49.59 2.233 0.742 0.662 54.37 29.01 3427.55 1.53 2.00
HIDROCICLONES DE 25 PULGADAS DIAMETRO
200.00 25 43.97 2.233 0.742 0.662 48.21 29.01 2380.24 2.20 3.00
180.00 25 43.97 2.233 0.764 0.662 49.65 26.11 2258.09 2.32 3.00
160.00 25 43.97 2.233 0.790 0.662 51.31 23.21 2128.95 2.46 3.00
140.00 25 43.97 2.233 0.820 0.662 53.27 20.31 1991.45 2.63 3.00
HIDROCICLONES DE 20 PULGADAS DIAMETRO
160.00 20 37.95 2.233 0.790 0.662 44.29 23.21 1362.53 3.84 4.00
140.00 20 37.95 2.233 0.820 0.662 45.97 20.31 1274.53 4.11 5.00
110.00 20 37.95 2.233 0.877 0.662 49.19 15.95 1129.75 4.64 5.00
100.00 20 37.95 2.233 0.901 0.662 50.52 14.50 1077.17 4.86 5.00
HIDROCICLONES DE 15 PULGADAS DIAMETRO
100.00 15 31.39 2.233 0.901 0.662 41.78 14.50 605.91 8.64 9.00
90.00 15 31.39 2.233 0.928 0.662 43.03 13.05 574.82 9.11 10.00
70.00 15 31.39 2.233 0.995 0.662 46.17 10.15 506.94 10.33 11.00
55.00 15 31.39 2.233 1.065 0.662 49.39 7.98 449.36 11.66 13.00
40.00 15 31.39 2.233 1.164 0.662 54.00 5.80 383.21 13.67 14.00
