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577103643-Calculations-Module-2021-Edition-Mineral-Processing
Calculations-Module-2021-Edition-Mineral-Processing .pdf

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University of KwaZulu-Natal- Westville Campus* CHEM FANDS ENCH2EF Material Science Sep 16, 2024 31
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ZIMBABWE SCHOOL OF MINES

Serving the SADC Mining Industry

QUESTION 1
Page 1 of 31
A slurry stream containing quartz is diverted into a 1-litre density can. The time taken to fill
the can is measured as 7 sec. The pulp density is measured by means of a calibrated balance,
and is found to be 1400 kg/m3. Calculate the % solids by weight, and the mass flow rate of Q+A AI homework help
Explanations instantly
quartz within the slurry.

SOLUTION 1
The density of quartz is 2650 kg/m3.

100s(D−1000)
% solids by weight = D(s−1000)
; Where D is pulp density (kg ⁄ m 3 ), s is density of solids (kg⁄ m3 )

100×2650×(1400−1000)
% solids by weight= 1400×(2650−1000)
= 45.9%
1 3600
The volumetric flow rate (F) = 7 litres ⁄ second = 7000
m3 ⁄ h = 0.15 m 3 ⁄ h
0.51×1400×45.9
Therefore, mass flow rate= = 330.5 𝒌? ⁄ ?
100

QUESTION 2
A pump is fed by two slurry streams. One stream has a flow rate of 5.0m3/h and contains 40%
solids by weight. The other stream has a flow rate of 3.4m3/h and contains 55% solids.
Calculate the tonnage of dry solids pumped per hour. (Density of solids is 3000 kg/m3.)

SOLUTION 2
Slurry stream 1 has a flow rate of 5_0m3/h and contains 40% solids.

100s(D−1000)
% solids by weight (x) = ; Where D is pulp density (kg ⁄ m 3 ), s is density of solids (kg⁄ m 3 ) .
D(s−1000)

Rearranging gives:

1000×100? 1000×100×3000
D= ?(100−?)+1000? = (3000×60)+(1000×40)
= ????𝒌? 𝒎⁄ ?

Therefore, the mass flow rate of solids in slurry stream 1 is given by:
𝐹?(?−1000) 5.0×3000×(1364−1000)
𝑀= ?? ⁄ ℎ = ?? ⁄ ℎ = ?.?? 𝒕 ?⁄
(?−1000) (3000−1000)
1000×100?
Slurry stream 2 has a flow rate of 3.4m3 /h and contains 55% solids. Using the equation: D= ?(100−?)+1000?

Compiled by:Eng. A. Rungani +263778817943 [email protected] 2021 files Page 1

ZIMBABWE SCHOOL OF MINES

Serving the SADC Mining Industry

The pulp density of the stream = 1579 kg/m3 . Therefore, the mass flow rate of solids in slurry stream 2 = 1.82 t/h.
The tonnage of dry solids pumped is thus: 1.82 + 2.73 = 4.55t/h
In some cases it is necessary to know the % solids by volume. This is a parameter sometimes used in mathematical
models of unit processes.
% solids by volume = xD
s

Also of use in milling calculations is the ratio of the weight of water to the weight of solids in the slurry, or the dilution
ratio. This is defined as:
Dilution ratio = 100−x
x
This is particularly important as the product of dilution ratio and weight of solids in the pulp is equal to the weight
of water in the pulp.

QUESTION 3
A flotation plant treats 500t of solids per hour. The feed pulp, containing 40% solids by weight,
is conditioned for 5 min with reagents before being pumped to flotation. Calculate the volume
of conditioning tank required. (Density of solids is 2700 kg/m3 .)
SOLUTION 3
The volumetric flow rate of solids in the slurry stream = mass flow rate/density
500×1000
= = 185.2 m 3 ⁄ h
2700
The mass flow rate of water in the slurry stream = mass flow rate of solids × dilution ratio
500 × (100 − 40)
= = 750 t ⁄h
40

Therefore, volumetric flow rate of water = 750m3/h.

Volumetric flow rate of slurry = 750+182.2= 935.2m3/h.
935.2×5
Therefore, for a nominal retention time of 5 min, the conditioning tank should have a volume of = 77.9m3.
60

QUESTION 4
Calculate the % solids content of the slurry pumped from the sump in question 2.

SOLUTION 4
The mass flow rate of solids in slurry stream 1 is 2.73 t/h. The slurry contains 40% solids, hence the mass flow
2.73×60
rate of water = 40
= 4.10 t ⁄ h
1.82×45
Similarly, the mass flow rate of water in slurry stream 2 = 55
= 1.49 t ⁄h

Total slurry weight pumped = 2.73+4.10+1.82+1.49 =10.14 t/h

Compiled by:Eng. A. Rungani +263778817943 [email protected] 2021 files Page 2

ZIMBABWE SCHOOL OF MINES

Serving the SADC Mining Industry

4.55×100
Therefore, % solids by weight = = 44.9%
10.14

QUESTION 5
The feed to a flotation plant assays 0.8% copper. The concentrate produced assays 25% Cu,
and the tailings 0.15% Cu. Calculate the recovery of copper to the concentrate, the ratio of
concentration, and the enrichment ratio.

SOLUTION 5
Cc 100c(f−t) 100×25(0.8−0.15%
The concentrator recovery is R = × 100% = %= = 81.7%
Ff f(c−t) 0.8(25−0.15)

F c−t 25−0.15
The ratio of concentration = = = = 38.2
C f−t 0.8−0.15

c 25
The enrichment ratio = = = 31.8
f 0.8

QUESTION 6
A plant treats 210.0 t of material during a shift, assaying 2.5% metal, to produce a concentrate
of 40% metal and a tailing of 0.20% metal. Copy and complete the table below.

ITEM WEIGHT /t ASSAY /% WEIGHT DISTRIBUTION

METAL/t METAL / t
FEED 210.0 2.5
CONCENTRATE 40
TAILINGS 0.2

SOLUTION 6
ITEM WEIGHT /t ASSAY /% WEIGHT METAL/t DISTRIBUTION
METAL / t
FEED 210.0 2.5 5.25 100.0
CONCENTRATE 12.1 40 4.84 92.2
TAILINGS 197.9 0.2 0.40 7.8

F c−t 40−0.2
The ratio of concentration = = = = ??.??
C f−t 0.2.5−0.2

Compiled by:Eng. A. Rungani +263778817943 [email protected] 2021 files Page 3

ZIMBABWE SCHOOL OF MINES

Serving the SADC Mining Industry

The tailing weight is thus 210.0−12.1=197.9 t.

The metallurgical balance for the shift is tabulated in the Table above.

QUESTION 7
In the circuit shown below, the rod mill is fed at the rate of 20 t/h of dry solids (density 2900
kg/m3). The cyclone feed contains 35% solids by weight, and size analyses on the rod mill
discharge, ball mill discharge, and cyclone feed gave:
Rod mill discharge 26.9%+250μm
Ball mill discharge 4.9%+250μm
Cyclone feed 13.8%+250μm
Calculate the volumetric flow rate of feed to the cyclone.

SOLUTION 7

A material balance on the cyclone feed junction gives:

F =20+B
Where F = cyclone feed, and B =ball mill discharge.
Therefore F = 20 + (F − 20), and a balance of +250 µm material gives:
13.8F =(26.9×20) +(F −20)×4.9 giving F =49.4 t/h.
49.4×1000
Volumetric flow rate of solids= 2900
= 17.0 m 3 ⁄ h

49.4×65
Volumetric flow rate of water = 35
= 91.7 m 3 ⁄ h

Therefore, flow rate of feed to the cyclone =17.0+91.7 =108.7m3 ⁄ h

Compiled by:Eng. A. Rungani +263778817943 [email protected] 2021 files Page 4

ZIMBABWE SCHOOL OF MINES

Serving the SADC Mining Industry

QUESTION 8
A cyclone is fed at the rate of 20 t/h dry solids. The cyclone feed contains 30% solids, the
underflow 50% solids, and the overflow 15% solids by weight. Calculate the tonnage of solids
per hour in the underflow.
SOLUTION 8
70
Dilution ratio of feed slurry = = 2.33
30
50
Dilution ratio of underflow = 50
= 1.00
85
Dilution ratio of overflow = 15
= 5.67

A material balance on the cyclone gives: 20 = U +V

Where U = tonnes of dry solids per hour in underflow; V = tonnes of dry solids per hour in overflow. Since the
weight of water entering the cyclone equals the weight of water leaving:
20×2.33=1.00U +5.67V or
46.6=U +5.67(20−U) which gives U =14.3 t/h

QUESTION 9
A laboratory hydrocyclone is fed with slurry of quartz (density 2650 kg/m3) at a pulp density
of 1130 kg/m3. The underflow has a pulp density of 1280 kg/m3 and the overflow 1040 kg/m3.
A 2-litre sample of underflow was taken in 3.1 s. Calculate the mass flow rate of feed to the
cyclone.
SOLUTION 9
% of solids in the feed is given by:
100s(D−1000)
% solids by weight (x) = ; Where D is pulp density (kg ⁄ m 3 ), s is density of solids (kg⁄ m 3 ) .
D(s−1000)
100×2650(1130−1000) 100×2650×130
= 1130(2650−1000)
= 1130×1650
= 18.5%

Similarly:
% solids content of underflow=35.1%
% solids content of overflow=6.2%
Therefore, dilution ratios of feed, underflow, and overflow are 4.4, 1.8, and 15.1 respectively.
2 2×3600
Volumetric flow rate of underflow = litres ⁄ s = m3 ⁄ h = 2.32 m 3 ⁄ h
3.1 3.1×1000

Therefore, mass flow rate of underflow is given by:

FDx .2.32×1280×35.1
M= kg⁄ h = kg⁄ h = 1042.3 kg ⁄h = 1.04 t ⁄ h
100 100

Where: F (m3 ⁄ h) = volumetric flow rate, D (kg ⁄ m 3 ) = pulp density,x = % solids by weight

Compiled by:Eng. A. Rungani +263778817943 [email protected] 2021 files Page 5

ZIMBABWE SCHOOL OF MINES

Serving the SADC Mining Industry

M (kg⁄ h) = mass flow rate of dry solids in slurry

Therefore, from a water balance on the cyclone: 4.4F =1.04×1.8+ (F −1.04) ×15.1
Which gives mass flow rate of feed (F) = 1.29 t/h

QUESTION 10
The flow sheet shown below illustrates a conventional closed circuit grinding operation. The
cyclone overflow line is instrumented with a magnetic flow meter and nuclear density gauge,
and the mass of dry ore fed to flotation is 25 t/h. The feed from the fine ore bins is sampled,
and is found to contain 5% moisture. The cyclone feed contains 33% solids, the cyclone
underflow 65% solids, and the overflow 15% solids. Calculate the circulating load on the
circuit and the amount of water required to dilute the ball mill discharge.

SOLUTION 10

A water balance on the cyclone gives:

67F 85×25 35U
= +
33 15 65

Where, F = cyclone feed (dry t/h); U = cyclone underflow (dry t/h).

The mass flow rate of feed from the ore bin = 25t/h (since input to circuit = output).
Therefore, F =25+U and
(25 +U)×67 25×85 35U
= +
33 15 65

From which U =61.0 dry t/h.

61.0
The circulating load is therefore 61.0 t/h and the circulating load ratio is 25
= 2.44

The ball mill feed = ore from bin + circulating load

Compiled by:Eng. A. Rungani +263778817943 [email protected] 2021 files Page 6

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