Moly-Cop Tools, Version 3.

0
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. Gutiérrez and J. E.
Sepúlveda, Dimensionamiento y Optimización de Plantas Concentradoras Mediante Técnicas de Modelación
Matemática, 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 = actual cyclone classification efficiency (fractional partition) for particles of size d i.

E ic = corrected cyclone classification efficiency for particles of size d i, excluding the feed slurry
short
circuit.
Bpf = 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

Q1.46 exp( -7.63+ 10.79  2 )

H = a1 ______________________________________________

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

where,

H = cyclone feed pressure, expressed in equivalent ft of feed slurry.

Q = volumetric cyclone feedrate, m 3/hr.
 = fraction of solids in the cyclone feed, by volume.

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 Moly-Cop Tools, Version 3.0
About the Cyclosim_Single Spreadsheet ...

DC = cyclone diameter, in.

h = cyclone free height, defined as the distance from the bottom of the vortex finder down to the
top
of the apex, in.
DI = cyclone feed inlet diameter (circle area equivalent if the inlet is rectangular), in.
DO = cyclone vortex finder diameter, in.
DU = 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, d50c.

The corrected cut size d50c 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 :

(DC)0.44 (DI)0.58 (DO)1.91 exp( 11.12  )

d50
c
= a2 _______________________________________________

(DU)0.80 h0.37 Q0.44 (  s - 1 )0.5

where a2 is also an application dependent constant to be determined in a similar fashion as a 1.

Correlation 3 : Flow Split.

Qu h0.19 (DU/DO)2.64 exp( -4.33+8.77 2 )

S = ______
= a3 _________________________________________________

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 a 3 is to be determined as a1 and a2.

Correlation 4 : Corrected Classification Efficiency.

Eic = 1 - exp [ - 0.693 (di/d50c)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 = l Bpw

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 Moly-Cop Tools, Version 3.0
About the Cyclosim_Single Spreadsheet ...

where l is the 5th application dependent constant, like the previous a 1, a2, a3 and a4 and where the water by-pass
Bpw may be obtained from :

S/(S+1) -  R s
c

Bpw = ____________________________

1 -  [ 1 - l(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
Rs
c
=  fi Eic
i=1

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, d 50c, 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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 Moly-Cop Tools TM
(Version 3.0)
CYCLOSIM
HYDROCYCLONE SIMULATOR
Simulation N° 1

Remarks Base Case Example

# of Cyclones Geometry, inches

Cyclones Diameter Height Inlet Vortex Apex
3 26.00 75.00 9.25 7.50 6.00
Default Values: 78.00 6.50 9.10 3.75

Operating Conditions : Ore Density, ton/m3 2.70

Cyclone Feed Conditions

Dry Tons Water Slurry Flow Density % Solids % Solids
ton/hr m3/hr ton/hr m3/hr ton/m3 (by volume) (by weight)
1204.07 593.05 1797.12 1039.00 1.730 42.92 67.00

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse)

a1 a2 a3 a4 l Bp (coarse)
3.172 0.757 10.652 0.760 0.910 0.000
9.932 1.361 52.968 0.441 0.950 0.000 Default Values

Feed Size Distribution :

i Mesh Opening Mid-Size ton/hr % Ret % Pass

1 1.05 25400 30206 0.00 0.00 100.00
2 0.742 19050 21997 0.00 0.00 100.00
3 0.525 12700 15554 99.01 8.22 91.78
4 0.371 9500 10984 81.02 6.73 85.05
5 3 6700 7978 59.45 4.94 80.11
6 4 4750 5641 37.80 3.14 76.97
7 6 3350 3989 34.08 2.83 74.14
8 9 2000 2588 50.50 4.19 69.95
9 10 1700 1844 30.54 2.54 67.41
10 14 1180 1416 57.44 4.77 62.64
11 20 850 1001 73.42 6.10 56.54
12 28 600 714 94.01 7.81 48.73
13 35 425 505 102.59 8.52 40.21
14 48 300 357 101.00 8.39 31.83
15 65 212 252 75.27 6.25 25.57
16 100 150 178 51.09 4.24 21.33
17 150 106 126 35.67 2.96 18.37
18 200 75 89 27.12 2.25 16.12
19 270 53 63 22.70 1.89 14.23
20 400 38 45 17.75 1.47 12.76
21 -400 0 19 153.61 12.76 0.00

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 Total 1204.07 100.00

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 Moly-Cop Tools TM
(Version 3.0)

CYCLOSIM
Hydrocyclone Simulator Sample N° 1

Remarks : Base Case Example

Number of Cyclones : 3 Operating Conditions :

Cyclone Dimensions, in : Feed Flowrate, m3/hr 1039.0
Diameter 26.00 Pressure, psi 4.1
Height 75.00 D50 (corr.), microns 180.8
Inlet 9.25 Water By-Pass, % 33.8
Vortex 7.50 Solids By-Pass, % 30.8
Apex 6.00 Plitt's Parameter 1.90
Ore Density, ton/m3 2.70 Circulating Load, % 493

Size Distributions, % Passing Classifier Efficiency

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

1.05 25400 30206 100.00 100.00 100.00 1.000 1.000

0.742 19050 21997 100.00 100.00 100.00 1.000 1.000
0.525 12700 15554 91.78 90.11 99.99 1.000 1.000
0.371 9500 10984 85.05 82.02 99.98 1.000 1.000
3 6700 7978 80.11 76.08 99.98 1.000 1.000
4 4750 5641 76.97 72.31 99.97 1.000 1.000
6 3350 3989 74.14 68.90 99.97 1.000 1.000
9 2000 2588 69.95 63.86 99.97 1.000 1.000
10 1700 1844 67.41 60.81 99.96 1.000 1.000
14 1180 1416 62.64 55.07 99.96 1.000 1.000
20 850 1001 56.54 47.74 99.95 1.000 1.000
28 600 714 48.73 38.35 99.94 1.000 1.000
35 425 505 40.21 28.16 99.66 0.994 0.992
48 300 357 31.83 18.64 96.87 0.944 0.919
65 212 252 25.57 12.54 89.88 0.812 0.728
100 150 178 21.33 9.23 81.00 0.647 0.491
150 106 126 18.37 7.41 72.43 0.512 0.295
200 75 89 16.12 6.26 64.71 0.422 0.166
270 53 63 14.23 5.43 57.66 0.370 0.090
400 38 45 12.76 4.82 51.90 0.341 0.048
-400 0 19 0.314 0.010

D80, microns 6621 8461 144.3

Ore, ton/hr 1204.1 1001.1 203.0 Classifier Constants

Water, m3/hr 593.0 200.4 392.6 a1 3.172

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 Slurry, ton/hr 1797.1 1201.5 595.6 a2 0.757
Slurry, m3/hr 1039.0 571.2 467.8 a3 10.652
Slurry Dens., ton/m3 1.730 2.103 1.273 a4 0.760
% Solids (by volume) 42.9 64.9 16.1 l 0.910
% Solids (by weight) 67.0 83.3 34.1 Bpc 0.000187

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Data
Cyclones Geometry, inches
Diameter Height Inlet Vortex Apex
26.0 75.0 9.25 7.50 6.00

Operating Conditions :
ton/m3 (by volume) s ton/hr m3/hr
346.33 0.429 2.70 401.36 197.68

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse)

a1 a2 a3 a4 l
3.172 0.757 10.652 0.760 0.910

Calculations

Correlation 1. Cyclone Feed Pressure, ft.

H 5.4550421

Correlation 2. Corrected Cut Size, microns.

d50c 180.81227

Correlation 3. Slurry Split.

S 1.2213295

Correlation 4. Classification Efficiency.

Water Water
m (Plitt) Rsc Bpw Bpf Bpc U'flow % Sol. O'flow % Sol.
1.89518028 0.7567565 0.33795581 0.30754892 0.0001872 66.808083 83.319051 130.87481 34.079328
Fraction Tyler Opening di* Feed Ei Rsc,i Ei Underflow Overflow
# Mesh micr. micr. ton % Ret. (corr) = fi Eic (real) ton % Ret. ton % Ret.

1 1.05 25400 30206 0.00 0.00 1.000 0.000 1.000 0.00 0.00 0.00 0.00
2 0.742 19050 21997 0.00 0.00 1.000 0.000 1.000 0.00 0.00 0.00 0.00
3 0.525 12700 15554 33.00 8.22 1.000 0.082 1.000 33.00 9.89 0.01 0.01
4 0.371 9500 10984 27.01 6.73 1.000 0.067 1.000 27.00 8.09 0.01 0.01
5 3 6700 7978 19.82 4.94 1.000 0.049 1.000 19.81 5.94 0.00 0.01
6 4 4750 5641 12.60 3.14 1.000 0.031 1.000 12.60 3.78 0.00 0.00
7 6 3350 3989 11.36 2.83 1.000 0.028 1.000 11.36 3.40 0.00 0.00
8 9 2000 2588 16.83 4.19 1.000 0.042 1.000 16.83 5.04 0.00 0.00
9 10 1700 1844 10.18 2.54 1.000 0.025 1.000 10.18 3.05 0.00 0.00
10 14 1180 1416 19.15 4.77 1.000 0.048 1.000 19.14 5.74 0.00 0.01
11 20 850 1001 24.47 6.10 1.000 0.061 1.000 24.47 7.33 0.00 0.01
12 28 600 714 31.34 7.81 1.000 0.078 1.000 31.33 9.39 0.01 0.01
13 35 425 505 34.20 8.52 0.992 0.085 0.994 34.01 10.19 0.19 0.28
14 48 300 357 33.67 8.39 0.919 0.077 0.944 31.78 9.52 1.89 2.79
15 65 212 252 25.09 6.25 0.728 0.046 0.812 20.36 6.10 4.73 6.99
16 100 150 178 17.03 4.24 0.491 0.021 0.647 11.02 3.30 6.01 8.88
17 150 106 126 11.89 2.96 0.295 0.009 0.512 6.09 1.82 5.80 8.58
18 200 75 89 9.04 2.25 0.166 0.004 0.422 3.82 1.14 5.22 7.72
19 270 53 63 7.57 1.89 0.090 0.002 0.370 2.80 0.84 4.77 7.05
20 400 38 45 5.92 1.47 0.048 0.001 0.341 2.02 0.60 3.90 5.76
21 -400 0 19 51.20 12.76 0.010 0.001 0.314 16.09 4.82 35.11 51.90

TOTAL 401.36 100.00 0.757 333.70 100.00 67.66 100.00

Circulating Load : 4.93