MEAMTA2

Learning Unit 4(1): Tutorial Memo

Question 1. Determination of the plant recovery

c ∗ (f − t)
R= ∗ 100
f ∗ (c − t)

0.25 ∗ (0.8 − 0.15)

R= ∗ 100
0.8 ∗ (0.25 − 0.15)

R = 31.25 ∗ (0.026)

𝐑 = 𝟖𝟏. 𝟕𝟒%

Question 2.1: Calculation of the Shift 1 Performance of the plant

F = 210t

f = 2.5%

c = 40%

t = 0.20 %

F c−t
=
C f−t

F 40 − 0.20
=
C 2.5 − 0.20

210
= 17.30
C

210
𝐶= = 12.1t
17.30

Shift 1 Performance

Items Weight (t) Assays (%) Weight (t) Distribution metal (%)
Feed 210 2.5 5.25 100
Concentrate 12.1 40 4.84 92.1
Tails 197.9 0.20 0.40 7.62
Question 2.2. Determination of the Shift 2performance

C f−t
=
F c−t

F 2.1 − 0.15
=
C 35 − 0.15

C
= 0.056
305

C = 305 ∗ 0.056 = 17.1t

Shift 2 Performance

Items Weight (t) Assays (%) Weight (t) Distribution metal (%)
Feed 305 2.1 6.41 100
Concentrate 17.1 35.0 5.99 93.45
Tails 287.9 0.15 0.43 6.72

Question 2.3. Determination of the combined performance

Combined Performance

Items Weight (t) Assays (%) Weight (t) Distribution metal

(%)
Feed 305+210= 515 2.3 = (11.66/515) 6.41+5.25=11.66 100
*100
Concentrate 17.1+12.1= 29.2 37.1 5.99+4.84=10.83 92.9
Tails 287.9+197.9= 0.17 0.43+0.40= 0.83 7.1
485.8

Weight average assays of the stream and a perfect balance is always produced by this method as
the two-product equation is consistent with the available data

Ff − Cc − Tt = 0
Question 2.4 Accounting for losses

Losses Accounting

Items Weight (t) Assays (%) Weight (t) Distribution metal (%)
Feed 515 2.3 11.66 100
Concentrate 28.8 (weighed) 37.1 10.68 91.6
Unaccounted loss - - 0.15 1.3
Tails 485.8 0.17 0.83 7.1

The actual recovery is 91.6% and any discrepancy in metal weight is regarded as an unaccounted
loss (1.3 %)

Question 3: Calculation of the monthly concentrate production

Beginning of the month

Weight (t) Assays (%) Weight (t)

Thickeners 210 44.1 92.6
Agitators & filters 15 43.9 6.6
In transit to smelter 20.7 45.4 97.1
Total inventory 432 45.4 196.3

End of the month

Weight (t) Assays (%) Weight (t)

Thickeners 199 39.6 78.8
Agitators & filters 25 40.8 10.2
In transit to smelter 262 39.3 103.0
Total inventory 486 39.5 192
Monthly concentrate production

Weight (t) Assays (%) Weight (t)

Concentrate received 3102 41.5 1287.3
Inventory Change +54 - -4.3
Production 3156 40.7 1283.0

In this case, there has been increase in the production of material, which obviously increases the
production but a decrease in the inventory of metal which lowers the metal production.

Question 4: Accounting for losses

F = 28760t

f = 1.1%

c = 24.9 %

t = 0.12 %

Beginning of the month → 257 t of concentrate in transit to the smelter

At the end of the month → 210 t of concentrate in transit to the smelter

Concentrate received = 1090.7t

Assay of the concentrate received = 24.7%

Losses Accounting

Items Weight (t) Assays (%) Weight (t) Distribution metal (%)
Feed 28760.0 1.1 316.4 100
Inventory Change 210-257=-47 - - -
Concentrate 1090.7-47= 1043.7 24.9 259.9 82.1
Unaccounted loss - - 23.2 7.3
Tails 27716.3 0.12 33.3 10.5
Question 5: Determination of the volumetric flowrate to the hydrocyclone

𝐎𝐅 = 𝐄
𝐇𝟐 𝐎 𝐇𝟐 𝐎

26% ± 250 𝜇𝑚 13 % ± 250 𝜇𝑚

𝐅 = 𝟐𝟎𝐭/𝐡 𝐇. 𝐂
𝐑𝐎𝐃 𝐌𝐈𝐋𝐋 𝐁
𝑪 𝑥 = 35%
𝐀

4.9% ± 250 μm
UF = 𝐅

𝑮
𝐁𝐀𝐋𝐋 𝐌𝐈𝐋𝐋

kg
s = 2900
m3

F = 20t/h

x = 35% at the cyclone feed

Size analysis

Rod mill discharge 26% ± 250μm

Ball mill discharge 4.9 % ± 250μm

Cyclone feed 13 % ± 250μm

CF = UF + OF

cyclone feed = Ball mill discharge + Rod mill discharge

D = E + F (1)
A = B = D (2)
{
C = G + B (3)
C=D (4)
D=E+F

D ∗ 13 = E ∗ 26 + F ∗ 4.9

D ∗ 13 = (D − 20) ∗ 4.9 + 20 ∗ 26

D ∗ 13 = 4.9 D − (4.9 ∗ 20) + (20 ∗ 26)

13D − 4.9D = 422

8.1D = 422

422
D= = 52.1 t/h
8.1

𝐂𝐅 = 𝟓𝟐. 𝟏𝐭/𝐡

𝐌𝐒
𝐕𝐒 =
𝐬

52.1
VS = = 𝟏𝟕. 𝟗𝟔 𝐦𝟑 /𝐡
2.9

Cyclone feed mass flow rate = Ms ∗ x ′

Mw = Ms ∗ x ′

100 − 35
Mw = 52.1 ∗
35

𝐌𝐰 = 𝟗𝟔. 𝟕𝐭/𝐡

Vw = MW = 96.7t/h (1m3 = 1t for water)

Volume of pulp at the hydrocyclone feed = 17.96 + 96.7 = 𝟏𝟏𝟒. 𝟕𝐦𝟑 /𝐡

Question 8
8.1. Determination of the circulating load ratio

Mass recirculated
circulating load ratio =
Fresh feed

Mass recirculated (UF)

circulating load ratio =
Fresh feed

Fresh feed = Overflow

Cyclone overflow (OF) = Cyclone feed(CF) − cyclone underflow(UF)

65
OF = 1077 − ( ) ∗ 1077 = 377 t/h
100

700
circulating load ratio = = 𝟏. 𝟖𝟔 = 𝟏𝟖𝟔%
377

8.2. Determination of the concentration per volume of solids in the hydrocyclone feed
 𝐕𝐬
𝐱=
𝐕𝐩

𝐌𝐬
𝐕𝐬 =
𝐬

1077
Vs = = 335m3 /h
3.215

Vp = Vs + Vwater

Mw
Vw =
w

Mw = Ms ∗ x ′

100 − 𝑥
Mw = 1077 ∗
𝑥

s(D − 1000)
x= ∗ 100
D(s − 1000)

3.215(1.449 − 1)
x= ∗ 100
1.449(3.215 − 1)

3.215(1.449 − 1)
x= ∗ 100
1.449(3.215 − 1)

𝑥 = 45%

100 − 𝑥
Mw = 1077 ∗
𝑥

100 − 45
Mw = 1077 ∗
45

55
Mw = 1077 ∗
45
 55
Mw = 1077 ∗
45

Mw = 1316.3 t/h

𝐕𝐰 = 𝟏𝟑𝟏𝟔. 𝟑 𝐦𝟑 /𝐡

𝐕𝐩 = 𝐕𝐬 + 𝐕𝐰

Vp = 335 + 1316.3 = 1651.3 m3 /h

Vs 335
x= ∗ 100 = ∗ 100 = 20.29% = 20.3%
Vp 1651.3

xD
% solids by volume =
s

45 ∗ 1.449
% solids by volume = = 20.28 = 20.3%
3.215

8.3: Volume of water in hydrocyclone products

8.3.1. Volume of water in hydrocyclone feed

Water hydrocyclone feed = 1316.3m3 /h

8.3.2. Volume of water in hydrocyclone underflow

50
Water UF = ∗ water cyclone feed
100

50
Water UF = ∗ 1316.3 = 𝟔𝟓𝟖. 𝟐 𝒎𝟑 /𝒉
100

8.3.3. Volume of water in hydrocyclone overflow

Water OF = Water CF − Water UF

Water OF = 1316.3 − 658.2 = 𝟔𝟓𝟖. 𝟏𝒎𝟑 /𝒉

Question 9: Calculation of the volumetric flow rate to the hydrocyclone

D=1.32t/m3

kg⁄ t
S = 3000 m3 = 3 ⁄m3 (Solids density)

D = 1.32 t⁄m3 (Pulp density at the hydrocyclone feed)

M = 25 t⁄h (Mass flowrate)

Size analysis at the hydrocyclone

RMD = 30% + 150μm (RDM: Rod Mill Discharge)

BMD = 8% + 150μm (BMD: Ball Mill Discharge)

CF = 17% + 150μm (CF: Cyclone Feed)

9. 1. Determination of the volumetric flowrate of solids at the hydrocyclone feed

t
CF = 25 h + BMD (1)
CF ∗ 17 = RMD ∗ 30 + BMD ∗ 8(2)

From (1) → BMD = CF − RMD (3)

(3) in (2)gives:

17CF = 25 ∗ 30 + (CF − 25) ∗ 8 (3)

17CF = 750 + 8CF − 200

9CF = 550

CF = 61.1t/h

Volume of solids at the CF = Mass solids at the CF⁄Solids density

3
Volume of solids at the CF = 61.1⁄3 = 20.37 m ⁄h

9.2. Determination of the volumetric flowrate of water at the hydrocyclone feed

Mass of water at the CF = Mass flowrate of the CF ∗ dilution ratio of the CF

100 − XCF
Dilution ratio of the CF =
XCF

100S(D − 1000)
XCF =
D(S − 1000)

100 ∗ 3(1.32 − 1)
XCF =
1.32(3 − 1)

100 ∗ 3(1.32 − 1)
XCF =
1.32(3 − 1)

𝐗 𝐂𝐅 = 𝟑𝟔. 𝟑𝟔 %

61.1t 100 − 36.36

Mass of water at the CF = ∗( ) = 106.94 t/h
h 36.36
Volume of water at the CF = Mass of water at the CF⁄water density

Volumetric flowrate of water = Mass flowrate of water (1m3 = 1 ton)

𝐦𝟑
Volume of water at the CF = 106.94⁄1 = 𝟏𝟎𝟔. 𝟗𝟒
𝐡

9.3. Determination of the volumetric flowrate of the cyclone feed (solids water)

Volumetric flowrate of the cyclone feed = 20.37 + 106.94 = 𝟏𝟐𝟕. 𝟔𝟒𝐦𝟑 /𝐡

Question 10.

10.1: Determination of the circulating load ratio

𝐔 (𝐟 − 𝐯)(𝐮 − 𝟏𝟎𝟎𝟎)
= (𝟑. 𝟐𝟎)
𝐅 (𝐮 − 𝐯)(𝐟 − 𝟏𝟎𝟎𝟎)
 SW
DCF =
S − x(S − W)
2560 ∗ 1000
DCF =
45
2560 − 100 (2560 − 1000)

2560000 2560000
DCF = =
2560 − 702.00 1858.00
𝐤𝐠⁄
𝐃𝐂𝐅 = 𝟏𝟑𝟕𝟖
𝐦𝟑
U (f − v)(u − 1000)
=
F (u − v)(f − 1000)
U (1378 − 1188)(1757 − 1000)
=
F (1757 − 1188)(1378 − 1000)
U 143830
= = 0.67
F 215082
t
F = U + V = U + 100
hr
U
= 0.67
U + 100
0.67 ∗ (U + 100) = U

0.67 U + 67 = U

U − 0.67 = 67

0.33U = 67
𝟔𝟕
𝐔= = 𝟐𝟎𝟑. 𝟎𝟑𝟎 ≅ 𝟐𝟎𝟑 𝐭/𝐡𝐫
𝟎. 𝟑𝟑
F = U + V = 203 + 100 = 303 t/hr
𝐔 𝟐𝟎𝟑
𝐂𝐢𝐫𝐜𝐮𝐥𝐚𝐭𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐑𝐚𝐭𝐢𝐨 = = = 𝟐𝟎𝟑%
𝐏𝐥𝐚𝐧𝐭 𝐅𝐞𝐞𝐞𝐝 𝟏𝟎𝟎
10.2. Determination of the solids percentages of the ball mill discharge and the volumetric
flowrate of the sump water addition
100 − xUF
Water UF = MUF ∗
xUF
 100S(D − 1000)
xUF =
D(S − 1000)
100 ∗ 2560 ∗ (1757 − 1000)
xUF =
1757(2560 − 1000)
193792000
xF = = 70.70 %
2740920
29.30 5956.69
Water UF = 203 ∗ =
70.70 70.70
𝐖𝐚𝐭𝐞𝐫 𝐔𝐅 = 𝟖𝟒. 𝟐𝟓𝐦𝟑 /𝐡𝐫

Water Discharge Ball Mill = Water Underflow + Water added

25m3 m3
Water Discharge Ball Mill = 84. + 2.85
hr hr
𝐦𝟑
𝐖𝐚𝐭𝐞𝐫 𝐁𝐚𝐥𝐥 𝐌𝐢𝐥𝐥 𝐃𝐢𝐬𝐜𝐡𝐚𝐫𝐠𝐞 = 𝟖𝟕. 𝟏
𝐡𝐫
𝐌𝐏 𝐁𝐚𝐥𝐥 𝐌𝐢𝐥𝐥 𝐃𝐢𝐬𝐜𝐡𝐚𝐫𝐠𝐞 = 𝐌𝐬 𝐁𝐚𝐥𝐥 𝐌𝐢𝐥𝐥 𝐃𝐢𝐬𝐜𝐡𝐚𝐫𝐠𝐞 + 𝐌𝐰 𝐁𝐚𝐥𝐥 𝐌𝐢𝐥𝐥 𝐃𝐢𝐬𝐜𝐡𝐚𝐫𝐠𝐞

𝐌𝐩 𝐁𝐚𝐥𝐥 𝐌𝐢𝐥𝐥 𝐃𝐢𝐬𝐜𝐡𝐚𝐫𝐠𝐞 = 𝟐𝟎𝟑 + 𝟖𝟕. 𝟏 = 𝟐𝟗𝟎. 𝟒𝟎 𝐭/𝐡𝐫

10.3. Determination of the percentage solids in the ball mill discharge

𝐌𝐰 = 𝐌𝐬 ∗ 𝐱′
100 − x
Mw = Ms ∗
x
Mw ∗ x = Ms ∗ (100 − x)

87.1 ∗ x = 100Ms − Msx

87.1 ∗ x = (100 ∗ 203) − 203x

87.1x + 203 x = 100 ∗ 203 t/hr

t
290.4 x = 20300
hr
𝟐𝟎𝟑𝟎𝟎
𝐱= = 𝟔𝟗. 𝟗%
𝟐𝟗𝟎. 𝟒
10.4. Determination of the volumetric flow rate of the sump water addition

Water Cyclone Feed = Water Discharge Ball Mill + Water Sump Addition
Water Sump Addition = Water Cyclone Feed − Water Discharge Ball Mill
100 − 45
Water Sump Addition = 303 ∗ − 87.1
45
𝟓𝟓
𝐖𝐚𝐭𝐞𝐫 𝐒𝐮𝐦𝐩 𝐀𝐝𝐝𝐢𝐭𝐢𝐨𝐧 = 𝟑𝟎𝟑 ∗ − 𝟖𝟕. 𝟏 = 𝟐𝟖𝟑. 𝟐𝟑𝐦𝟑 /𝐡𝐫
𝟒𝟓

10.5. Determination of the pulp density of the hydrocyclone feed

SW
DCF =
S − x(S − W)
2560 ∗ 1000
DCF =
45
2560 − 100 (2560 − 1000)

2560000 2560000
DCF = =
2560 − 702.00 1858.00
𝐤𝐠⁄
𝐃𝐂𝐅 = 𝟏𝟑𝟕𝟖
𝐦𝟑