Mineral SG (g/cm3) Composition (%)

Find the bulk density of the ore given:

PbS 7.5 30
CuFeS2 4.2 10
ZnS 4.1 10
FeS2 5.0 50
Solution: Assume 100 g
Mineral Mass Density Volume
PbS 30 g 30 g / 7.5 g/cm3 4 cm3
𝒕𝒐𝒕𝒂𝒍 𝒎𝒂𝒔𝒔
𝒃𝒖𝒍𝒌 𝒅𝒆𝒏𝒔𝒊𝒕𝒚 =
CuFeS2 10 g 10 g / 4.2 g/cm3 2.38 cm3
𝒕𝒐𝒕𝒂𝒍 𝒗𝒐𝒍𝒖𝒎𝒆
ZnS 10 g 10 g / 4.1 g/cm3 2.44 cm3 100 𝑔
= 18.82 𝑐𝑚3
FeS2 50 g 50 g / 5.0 g/cm3 10 cm3
100 g 18.82 cm3 = 5.31 g/cm3
A 5500 tons of stockpiled concentrate with 12% moisture was shipped to a smelter plant after
a week of being in the stockyard. At shipment time, moisture was only 69% of the original.
What is the weight of the final concentrate?

Solution:
wt of orig concentrate = 5500 tons w/ 12% moisture
5500 T (0.88) = 4840 T of dry concentrate
5500 T (0.12) = 660 T of moisture (original)
*during shipment,
660 T (0.69) = 455.4 T remaining moisture

final concentrate wt = dry concentrate + remaining moisture

= 4840 + 455.4
= 5295.4 T
Find the % ball loading of the ball mill shown given inner diameter of 8.3m.

𝑯
% 𝒃𝒂𝒍𝒍 𝒍𝒐𝒂𝒅𝒊𝒏𝒈 = 𝟏𝟏𝟑 − 𝟏𝟐𝟔
𝑫
5.32
= 113 – 126
8.3
= 32.24%
Assume that the capacity of a ball mill varies directly with the length of the mill and with 2.6
power of diameter. If a 4’ x 4’ ball mill has a capacity of 20 tons per day, calculate the diameter
of a ball mill 5 feet long that would grind 100 tons per day.

Solution:
𝑪 ∝𝒍 𝒅 𝟐.𝟔

2.6
*solving for k, 𝐶1 = 𝑘 𝑙1 𝑑1
2.6
20 = 𝑘 𝑙1 𝑑1
k = 0.136

*solving for d2, 𝐶2 = 𝑘 𝑙2 𝑑2 2.6

100 = (0.136) (5′ ) 𝑑2 2.6

𝑑2 = 6.82’
A copper concentrator is to have a capacity of 2000 Ore 4” = 101 600 μm
tons per day. The proposed size reduction scheme is
shown on the right. Cone crusher

Assume a work index of 12 kWh/ton over the size P80 ½ ” = 12700 μm

range. The crusher is operating at 80% of the Rod mill
available time while the RM and BM are continuous. P80 20 mesh = 841 μm
Ball mill
Calculate the total power consumption of the 3
equipment in a day. P80 140 mesh = 105 μm
Product
Solution: Ore 4” = 101 600 μm
𝟏 𝟏
𝑾 = 𝟏𝟎 𝑾𝒊 −
√𝑷𝟖𝟎 √𝑭𝟖𝟎 Cone crusher
P80 ½ ” = 12700 μm
*for cone crusher,
1 1 Rod mill
𝑊 = 10 12 − P80 20 mesh = 841 μm
√12700 √101600
= 0.688 kWh/T Ball mill
P80 140 mesh = 105 μm
2000 𝑡 1 𝑑𝑎𝑦
𝑃 = 0.688 𝑘𝑊𝑕/𝑡 Product
𝑑𝑎𝑦 0.8 (24 𝑕𝑟𝑠)
= 71.67 kW
Solution: Ore 4” = 101 600 μm
𝟏 𝟏
𝑾 = 𝟏𝟎 𝑾𝒊 −
√𝑷𝟖𝟎 √𝑭𝟖𝟎 Cone crusher
P80 ½ ” = 12700 μm
*for rod mill,
1 1 Rod mill
𝑊 = 10 12 − P80 20 mesh = 841 μm
√841 √12700
= 3.07 kWh/T Ball mill
P80 140 mesh = 105 μm
2000 𝑡 1 𝑑𝑎𝑦
𝑃 = 3.07 𝑘𝑊𝑕/𝑡 Product
𝑑𝑎𝑦 24 𝑕𝑟𝑠
= 255.83 kW
Solution: Ore 4” = 101 600 μm
𝟏 𝟏
𝑾 = 𝟏𝟎 𝑾𝒊 −
√𝑷𝟖𝟎 √𝑭𝟖𝟎 Cone crusher
P80 ½ ” = 12700 μm
*for ball mill,
1 1 Rod mill
𝑊 = 10 12 − P80 20 mesh = 841 μm
√105 √841
= 7.57 kWh/T Ball mill
P80 140 mesh = 105 μm
2000 𝑡 1 𝑑𝑎𝑦
𝑃 = 7.57 𝑘𝑊𝑕/𝑡 Product
𝑑𝑎𝑦 24 𝑕𝑟𝑠
= 630.83 kW
Solution: Ore 4” = 101 600 μm
𝟏 𝟏
𝑾 = 𝟏𝟎 𝑾𝒊 −
√𝑷𝟖𝟎 √𝑭𝟖𝟎 Cone crusher
P80 ½ ” = 12700 μm
*for total power,
Rod mill
𝑃𝑡𝑜𝑡𝑎𝑙 = 𝑃𝑐𝑐 + 𝑃𝑟𝑚 + 𝑃𝑏𝑚
P80 20 mesh = 841 μm
= 71.67 + 255.83 + 630.83 Ball mill
= 958.33 kW P80 140 mesh = 105 μm
Product
Consider a binary mixture of galena (SG 7.5) and quartz (SG 2.65) particles being classified in
water. Determine the free-settling ratio from (a) Stoke’s Law and (b) Newton’s Law. What can
you conclude?

Solution:
(a) For small particles obeying Stoke’s Law, the free-settling ratio is:
1/2
𝑑𝑎 𝜌𝑏 − 𝜌𝑓
=
𝑑𝑏 𝜌𝑎 − 𝜌𝑓
7.5 ;1 1/2
= 2.65 ;1
= 1.99
Conclusion: A particle of galena will settle at the same rate as a particle of quartz which has
a diameter 1.99 times larger than the galena particle.
Consider a binary mixture of galena (SG 7.5) and quartz (SG 2.65) particles being classified in
water. Determine the free-settling ratio from (a) Stoke’s Law and (b) Newton’s Law. What can
you conclude?

Solution:
(b) For particles obeying Newton’s Law, the free-settling ratio is:
𝑑𝑎 𝜌𝑏 − 𝜌𝑓
=
𝑑𝑏 𝜌𝑎 − 𝜌𝑓
7.5 ;1
=2.65 ;1
= 3.94
Conclusion: The free-settling ratio is larger for coarse particles obeying Newton’s Law than
for fine particles obeying Stoke’s Law.
Waste clay from beneficiation plant discharge to a disposal impoundment is in slurry form. If
clay has SG of 2.7 and at 30% solids, find the volume of slurry containing 1 MT of clay.

Solution 1:
%𝑳 70
%𝑺 + 𝟏 +1
𝑫𝒑 = = 30 = 1.233 𝑇/𝑚3
%𝑳 𝟏 70 1
+
%𝑺 𝑺𝑮 30 2.7 +

𝒎𝒔 = 𝒙 𝒎𝒑
1 T = (0.3) (𝑚𝑝 )
𝑚𝑝 = 3.33 T

𝒎𝒑 3.33 𝑇 𝟑
𝑽𝒑 = = = 𝟐. 𝟕𝟎𝟑 𝒎
𝑫𝒑 1.233 𝑇/𝑚3
Waste clay from beneficiation plant discharge to a disposal impoundment is in slurry form. If
clay has SG of 2.7 and at 30% solids, find the volume of slurry containing 1 MT of clay.

Solution 2:
𝑽𝒑 = 𝑽𝒔 + 𝑽𝒘
𝒎𝒔 𝟏𝟎𝟎 ;𝒙
= + 𝒎𝒔 𝑫𝑹 ; 𝑫𝑹 =
𝑺𝑮 𝒙

1𝑇 100;30
= +1𝑇
2.7 𝑇/𝑚3 30

= 𝟐. 𝟕𝟎𝟑 𝒎𝟑
How much 43% solids should be added to form 10% solids of 1 liter volume? SG of ore = 3.1

Solution:
%𝑳 90
:𝟏 :1
%𝑺 10
V1 = water *for 10% solids: 𝑫𝒑 = %𝑳 𝟏 = 90 1 = 1.0727 𝑘𝑔/𝐿
: :
V2 %𝑺 𝑺𝑮 10 3.1
%𝑳 57
43% solids :𝟏 :1
%𝑺 43
*for 43% solids: 𝑫𝒑 = %𝑳 𝟏 = 57 1 = 1.411 𝑘𝑔/𝐿
: :
%𝑺 𝑺𝑮 43 3.1

1L
V1 + V2 = 1 L
𝑘𝑔
𝒎𝒑𝟏 = 𝑫𝒑𝟏 𝒙 𝑽𝒑𝟏 = 1.0727 𝐿 1 𝐿 = 1.0727 𝑘𝑔
10% solids 𝒎𝒑𝟏 = 𝒎𝒑𝟐 + 𝒎𝒘𝒂𝒕𝒆𝒓
1.0727 kg = (1.411 kg/L) V2 + (1 kg/L) V1
1.0727 = 1.411 V2 + (1- V2)
V2 = 0.177 L
A slurry stream containing quartz is diverted into a 1 L density can. The time taken to fill the
can is measured as 7 seconds. 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
quartz within the slurry. Density of quartz = 2650 kg/m3

Solution:
𝟏𝟎𝟎 𝑫𝒔 𝑫𝒑 ;𝟏𝟎𝟎𝟎 100 2650 (1400;1000)
*%solids: 𝒙= 𝑫𝒑 𝑫𝒔 ;𝟏𝟎𝟎𝟎
= 1400 (2650 ;1000)
= 𝟒𝟓. 𝟖𝟗%
1 𝑚3
𝒗𝒐𝒍 1𝐿𝑥
*volumetric flowrate: 𝑭= = 1 𝑚𝑖𝑛
1000 𝐿
1 ℎ𝑟 = 0.51 𝑚3 /𝑕𝑟
𝒕 7 𝑠 𝑥 60 𝑠 𝑥 60 𝑚𝑖𝑛
0.51 𝑚3 𝑘𝑔
𝑭 𝑫𝒑 𝒙 1400 (45.89)
ℎ𝑟 𝑚3
*mass flowrate: 𝑴= = = 𝟑𝟐𝟕. 𝟔𝟓 𝒌𝒈/𝒉𝒓
𝟏𝟎𝟎 100
A pump is fed by two slurry streams. Stream 1 has a flow rate of 5.0 m3/h and contains 40%
solids by weight. Stream 2 has a flow rate of 3.4 m3/h and contains 55% solids by weight.
Calculate the tonnage of dry solids pumped per hour given that the density of solids is 3000
kg/m3 as well as the % solids content of the slurry pumped from the sump.

Solution:

𝟏𝟎𝟎𝟎 𝟏𝟎𝟎 (𝑫𝒔 ) 1000 100 (3000)

𝑫𝒑𝟏 = = = 1364 𝑘𝑔/𝑚3
𝑫𝒔 𝟏𝟎𝟎 − 𝒙 + 𝟏𝟎𝟎𝟎𝒙 3000 100 − 40 + 1000 (40)

𝑭 𝑫𝒔 (𝑫𝒑 − 𝟏𝟎𝟎𝟎) 5 3000 (1364 − 1000)

𝑴𝒑𝟏 = = = 2.73 𝑇/𝑕𝑟
𝑫𝒔 − 𝟏𝟎𝟎𝟎 3000 − 1000
A pump is fed by two slurry streams. Stream 1 has a flow rate of 5.0 m3/h and contains 40%
solids by weight. Stream 2 has a flow rate of 3.4 m3/h and contains 55% solids by weight.
Calculate the tonnage of dry solids pumped per hour given that the density of solids is 3000
kg/m3 as well as the % solids content of the slurry pumped from the sump.

Solution:

𝟏𝟎𝟎𝟎 𝟏𝟎𝟎 (𝑫𝒔 ) 1000 100 (3000)

𝑫𝒑𝟐 = = = 1579 𝑘𝑔/𝑚3
𝑫𝒔 𝟏𝟎𝟎 − 𝒙 + 𝟏𝟎𝟎𝟎𝒙 3000 100 − 55 + 1000 (55)

𝑭 𝑫𝒔 (𝑫𝒑 − 𝟏𝟎𝟎𝟎) 3.4 3000 (1579 − 1000)

𝑴𝒑𝟐 = = = 2.95 𝑇/𝑕𝑟
𝑫𝒔 − 𝟏𝟎𝟎𝟎 3000 − 1000
A pump is fed by two slurry streams. Stream 1 has a flow rate of 5.0 m3/h and contains 40%
solids by weight. Stream 2 has a flow rate of 3.4 m3/h and contains 55% solids by weight.
Calculate the tonnage of dry solids pumped per hour given that the density of solids is 3000
kg/m3 as well as the % solids content of the slurry pumped from the sump.

Solution:

𝑴𝒕𝒐𝒕𝒂𝒍 = 𝑴𝒑𝟏 + 𝑴𝒑𝟐

= 2.73 + 2.95
= 5.68 TPH
A pump is fed by two slurry streams. Stream 1 has a flow rate of 5.0 m3/h and contains 40%
solids by weight. Stream 2 has a flow rate of 3.4 m3/h and contains 55% solids by weight.
Calculate the tonnage of dry solids pumped per hour given that the density of solids is 3000
kg/m3 as well as the % solids content of the slurry pumped from the sump.

Solution:
𝒎𝒔 𝟏𝟎𝟎 ;𝒙
%𝒔𝒐𝒍𝒊𝒅𝒔 = 𝒎𝒑
𝒙 𝟏𝟎𝟎 ; 𝒎𝒘𝒂𝒕𝒆𝒓 = 𝒎𝒔 𝒙 𝑫𝑹 ; 𝑫𝑹 = 𝒙

*for stream 1: 𝑚𝑠1 = 2.73 𝑇𝑃𝐻

100 ;40
𝑚𝑤𝑎𝑡𝑒𝑟1 = 2.73 = 4.095 𝑇𝑃𝐻
40
𝑚𝑝1 = 𝑚𝑠1 + 𝑚𝑤𝑎𝑡𝑒𝑟1 = 2.73 + 4.095 = 6.825 𝑇𝑃𝐻
A pump is fed by two slurry streams. Stream 1 has a flow rate of 5.0 m3/h and contains 40%
solids by weight. Stream 2 has a flow rate of 3.4 m3/h and contains 55% solids by weight.
Calculate the tonnage of dry solids pumped per hour given that the density of solids is 3000
kg/m3 as well as the % solids content of the slurry pumped from the sump.

Solution:
𝒎𝒔 𝟏𝟎𝟎 ;𝒙
%𝒔𝒐𝒍𝒊𝒅𝒔 = 𝒎𝒑
𝒙 𝟏𝟎𝟎 ; 𝒎𝒘𝒂𝒕𝒆𝒓 = 𝒎𝒔 𝒙 𝑫𝑹 ; 𝑫𝑹 = 𝒙

*for stream 2: 𝑚𝑠2 = 2.95 𝑇𝑃𝐻

100 ;55
𝑚𝑤𝑎𝑡𝑒𝑟2 = 2.95 = 2.41 𝑇𝑃𝐻
55
𝑚𝑝2 = 𝑚𝑠2 + 𝑚𝑤𝑎𝑡𝑒𝑟2 = 2.95 + 2.41 = 5.36 𝑇𝑃𝐻
A pump is fed by two slurry streams. Stream 1 has a flow rate of 5.0 m3/h and contains 40%
solids by weight. Stream 2 has a flow rate of 3.4 m3/h and contains 55% solids by weight.
Calculate the tonnage of dry solids pumped per hour given that the density of solids is 3000
kg/m3 as well as the % solids content of the slurry pumped from the sump.

Solution:
𝒎𝒔 𝟏𝟎𝟎 ;𝒙
%𝒔𝒐𝒍𝒊𝒅𝒔 = 𝒎𝒑
𝒙 𝟏𝟎𝟎 ; 𝒎𝒘𝒂𝒕𝒆𝒓 = 𝒎𝒔 𝒙 𝑫𝑹 ; 𝑫𝑹 = 𝒙

𝑚𝑠1 : 𝑚𝑠2
*for total: %𝑠𝑜𝑙𝑖𝑑𝑠𝑠𝑙𝑢𝑟𝑟𝑦 = 𝑚𝑝1 : 𝑚𝑝2
𝑥 100

2.73:2.95
= 6.825:5.36
𝑥 100

= 46.61%
A cyclone is fed at the rate of 20 TPH of 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:
F=U+V
20 = U + V

𝑭𝒇′ = 𝑼𝒖′ + 𝑽𝒗′ ; f’, u’, v’ are dilution ratios

100 − 30 100 − 50 100 − 15
20 =𝑈 + 20 − 𝑈
30 50 15
U = 14.29 TPH
A laboratory hydrocyclone is fed with a 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-L sample of underflow was taken in 3.1 seconds. Calculate the mass flow rate of feed to
the cyclone.

Solution:

(100)(2650)(1130;1000)
*%solids: 𝑥𝐹 = = 18.5%
(1130)(2650;1000)
(100)(2650)(1280;1000)
𝑥𝑈 = (1280)(2650;1000)
= 35.1%
(100)(2650)(1040;1000)
𝑥𝑂 = = 6.2%
(1040)(2650;1000)
A laboratory hydrocyclone is fed with a 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-L sample of underflow was taken in 3.1 seconds. Calculate the mass flow rate of feed to
the cyclone.

Solution:

1 𝑚3
2 𝐿 𝑥 1000 𝐿 𝑚3
*volumetric flowrate of underflow: 𝐹𝑈 = 1 𝑚𝑖𝑛 1 ℎ𝑟 = 2.32 𝑕𝑟
3.1 𝑠 𝑥 𝑥
60 𝑠 60 𝑚𝑖𝑛

2.32 𝑚3 𝑘𝑔
( )(1280 3 )(35.1%) 𝑘𝑔
ℎ𝑟 𝑚
*mass flowrate of underflow: 𝑀𝑈 = = 1042.33 𝑕𝑟 = 1.04 𝑇𝑃𝐻
100
A laboratory hydrocyclone is fed with a 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-L sample of underflow was taken in 3.1 seconds. Calculate the mass flow rate of feed to
the cyclone.

Solution:

*water balance: F=U+V

V = F – 1.04

𝑭𝒇′ = 𝑼𝒖′ + 𝑽𝒗′

100 − 18.5 100 − 35.1 100 − 6.2
F = 1.04 + 𝐹 − 1.04
18.5 35.1 6.2
F = 1.29 TPH
A cyclone overflow has a mass of dry ore fed to flotation at 25 t/h. The feed from the fine ore
bins 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 ratio on the
circuit and the amount of water required to dilute the ball mill discharge.
Ore Bin (5% moisture)
Solution:
Ball mill
*cyclone water balance: F = 25 + U water
67 85 35
25 + 𝑈 = 25 + 𝑈 Cyclone
33 15 65
U = 60.94 TPH

𝑼 60.94 u’ o’
*circulating load ratio: 𝑪𝑳𝑹 = 𝑭𝑭
= 25
= 𝟐. 𝟒𝟒
Flotation
A cyclone overflow has a mass of dry ore fed to flotation at 25 t/h. The feed from the fine ore
bins 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 ratio on the
circuit and the amount of water required to dilute the ball mill discharge.
Ore Bin (5% moisture)
Solution:
Ball mill
67 𝑚3
*water in cyclone feed: 𝑊𝐶𝐹 = 25 + 60.94 = 174.484 𝑕𝑟 water
33
Cyclone
35 5
60.94 65 : 25 95 𝑚3
*water in ball mill feed: 𝑊𝐵𝑀 = = 34.13
1 𝑇/𝑚3 𝑕𝑟
u’ o’

Flotation
A cyclone overflow has a mass of dry ore fed to flotation at 25 t/h. The feed from the fine ore
bins 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 ratio on the
circuit and the amount of water required to dilute the ball mill discharge.
Ore Bin (5% moisture)
Solution:
Ball mill
*water balance: 𝑊𝐶𝐹 = 𝑊𝐵𝑀 + 𝑊𝑎𝑑𝑑′𝑙 water
174.484 = 34.13 + 𝑊𝑎𝑑𝑑′ 𝑙
Cyclone
𝑊𝑎𝑑𝑑′𝑙 = 140.354 𝒎𝟑 /𝒉𝒓

u’ o’

Flotation
In the circuit shown, the rod mill is fed at the rate of 20 TPH of dry solids (density 2900 kg/m3).
Calculate the volumetric flow rate of cyclone feed. The cyclone feed contains 35% solids by
weight and size analyses on the rod mill discharge, ball mill discharge, and cyclone feed gave:
RM discharge: 26.9% +250μm
BM discharge: 4.9% +250μm
Cyclone feed: 13.8% +250μm F = 20
(C)
Solution:
*material balance at cyclone feed junction: B+F=C
B + 20 = C (B)
B = C – 20
B+F=C
(C – 20)(0.049) + (20)(0.269) = (C)(0.138)
C = 49.44 TPH = 𝑀𝑠
In the circuit shown, the rod mill is fed at the rate of 20 TPH of dry solids (density 2900 kg/m3).
Calculate the volumetric flow rate of cyclone feed. The cyclone feed contains 35% solids by
weight and size analyses on the rod mill discharge, ball mill discharge, and cyclone feed gave:
RM discharge: 26.9% +250μm
BM discharge: 4.9% +250μm
Cyclone feed: 13.8% +250μm F = 20
(C)
Solution:

*volumetric flowrate of solids: (B)

𝑇 𝑘𝑔
𝑴𝒔 49.44ℎ𝑟 𝑥 1000 𝑇
𝑽𝒔 = = = 17.05 𝑚3 /𝑕𝑟
𝑺𝑮 2900 𝑘𝑔/𝑚3
In the circuit shown, the rod mill is fed at the rate of 20 TPH of dry solids (density 2900 kg/m3).
Calculate the volumetric flow rate of cyclone feed. The cyclone feed contains 35% solids by
weight and size analyses on the rod mill discharge, ball mill discharge, and cyclone feed gave:
RM discharge: 26.9% +250μm
BM discharge: 4.9% +250μm
Cyclone feed: 13.8% +250μm F = 20
(C)
Solution:

*volumetric flowrate of water: (B)

𝑇 100;35
𝑴𝒘 = 𝑴𝒔 𝒙 𝑫𝑹 = 49.44 𝑕𝑟 = 91.82 TPH
35
𝑇 𝑘𝑔
𝑴𝒘 91.82ℎ𝑟 𝑥 1000 𝑇
𝑽𝒘 = 𝑫𝒘
= 1000 𝑘𝑔/𝑚3
= 91.82 𝑚3 /𝑕𝑟
In the circuit shown, the rod mill is fed at the rate of 20 TPH of dry solids (density 2900 kg/m3).
Calculate the volumetric flow rate of cyclone feed. The cyclone feed contains 35% solids by
weight and size analyses on the rod mill discharge, ball mill discharge, and cyclone feed gave:
RM discharge: 26.9% +250μm
BM discharge: 4.9% +250μm
Cyclone feed: 13.8% +250μm F = 20
(C)
Solution:

*volumetric flowrate of feed: 𝑽𝒑 = 𝑽𝒔 + 𝑽𝒘 (B)

= 17.05 + 91.82
= 108.87 𝒎𝟑 /𝒉𝒓
Calculate the circulating load in the grinding circuit shown below, and the amounts of water
added to the rod mill and cyclone feed.
Feed to RM = 55 TPH ; RM discharge = 62% solids
f = 48% solids ; o’ = 31% solids ; u’ = 74% solids

Solution:
*cyclone water balance: 𝑭𝒇′ = 𝑼𝒖′ + 𝑽𝒗′
52 26 69
55 + 𝑈 48 = 𝑈 + 55
74 31
U = 85.84 TPH = CL

*water in RM discharge = water addition to RM

38
𝑊𝑅𝑀 = 55 = 33.71 𝑇𝑃𝐻 = 33.71 𝑚3 /𝑕𝑟
62
Calculate the circulating load in the grinding circuit shown below, and the amounts of water
added to the rod mill and cyclone feed.
Feed to RM = 55 TPH ; RM discharge = 62% solids
f = 48% solids ; o’ = 31% solids ; u’ = 74% solids

Solution:
*water in BM discharge:
26
𝑊𝐵𝑀 = 85.84 74 = 30.16 𝑇𝑃𝐻 = 30.16 𝑚3 /𝑕𝑟
*water in cyclone feed:
52
𝑊𝐶𝐹 = (55 + 85.84) 48 = 152.577 𝑇𝑃𝐻 = 152.577 𝑚3 /𝑕𝑟
*water required in cyclone feed:
𝑊𝑟𝑒𝑞′ 𝑑 = 𝑊𝐶𝐹 − 𝑊𝑅𝑀 + 𝑊𝐵𝑀 = 152.577 − 33.71 + 30.16 = 𝟖𝟖. 𝟒𝟐 𝒎𝟑 /𝒉𝒓
In a metallurgical test, 400 g of ore X is blended with 700 g of ore Y to produce 2 L of slurry.
Find the resulting pulp density given SG of ore X to be 3.23 and ore Y to be 1.92.

Solution:
*volume of ores:
400 𝑔 700 𝑔
𝑉𝑥 = = 123.84 𝑐𝑚3 ; 𝑉𝑦 = = 364.58 𝑐𝑚3
3.23 𝑔/𝑐𝑚3 1.92 𝑔/𝑐𝑚3
*volume of water:
𝑉𝑤 = 𝑉𝑝 − 𝑉𝑥 + 𝑉𝑦 = 2000 𝑐𝑚3 − 123.84 + 364.58 = 1511.58 𝑐𝑚3
*mass of water:
𝑔
𝒎𝒘 = 𝝆𝒘 𝒙 𝑽𝒘 = 1 𝑐𝑚3 1511.58 𝑐𝑚3 = 1511.58 𝑔
*pulp density:
𝒎𝒑 𝒎𝒔 :𝒎𝒘 400:700 :1511.58 𝑔
𝑫𝒑 = = = = 𝟏𝟑𝟎𝟓. 𝟕𝟗 𝒈𝒑𝑳
𝑽𝒑 𝑽𝒑 2𝐿
At 50% volumetric loading, a certain ball mill whose inner volume is 10 L has a ball charge
consisting of 25 pcs of 1.5 in. diameter balls and 250 pcs of 1.0 in. diameter balls.
a. If the ore has a specific gravity of 2.8, what is the pulp density in terms of %solids?
b. If the pulp were to occupy the interstices between the balls, compute the weight of water
and ore required if the density of the pulp should be 1.5 g/cm3.

Solution:
(100)(2800)(1500;1000)
(a) x = = 𝟓𝟏. 𝟖𝟓%
(1500)(2800;1000)
(b) *volume of BM: 𝑉𝐵𝑀 = 0.50 10 𝐿 = 5 𝐿
𝟒
*volume of balls: 𝑽 = 𝟑 𝝅𝒓𝟑
4 1.5 3 4 1.0
𝑉𝑏𝑎𝑙𝑙𝑠 = 3
𝜋( 2
) 25 + 3 𝜋( 2 )3 250 = 175.08 𝑖𝑛3
2.54 𝑐𝑚 3 1𝑚 3 1000 𝐿
= 175.08 𝑖𝑛3 = 2.87 𝐿
1 𝑖𝑛 100 𝑐𝑚 1 𝑚3
At 50% volumetric loading, a certain ball mill whose inner volume is 10 L has a ball charge
consisting of 25 pcs of 1.5 in. diameter balls and 250 pcs of 1.0 in. diameter balls.
a. If the ore has a specific gravity of 2.8, what is the pulp density in terms of %solids?
b. If the pulp were to occupy the interstices between the balls, compute the weight of water
and ore required if the density of the pulp should be 1.5 g/cm3.

Solution:
(b) *volume of pulp: 𝑉𝑝 = 𝑉𝐵𝑀 − 𝑉𝑏𝑎𝑙𝑙𝑠 = 5 𝐿 − 2.87 𝐿 = 2.13 𝐿
𝑘𝑔 1 𝑚3
*mass of pulp: 𝑚𝑝 = 𝜌𝑝 𝑥 𝑉𝑝 = 1500 𝑚3 1000 𝐿 2.13 𝐿 = 3.195 𝑘𝑔
𝑚𝑠 𝑚𝑠
*weight of ore: 𝑥= 𝑥 100 51.85 = 𝑥 100 𝑚𝑠 = 𝟏. 𝟔𝟔 𝒌𝒈
𝑚𝑝 3.195
*weight of water: 𝑚𝑝 = 𝑚𝑠 + 𝑚𝑤 3.195 = 1.66 + 𝑚𝑤 𝑚𝑤 = 𝟏. 𝟓𝟒 𝒌𝒈
 F = 100 kg
40% 12mm
60% 25mm

O = 60 kg
10 kg 12mm
50 kg 25mm
U = 40 kg
30 kg 12mm
10 kg 25mm
 50 60 10 10 50 60
− 1 −
𝑈 𝑜−𝑓
50
−
60 60 100 40 40 60 − 100
𝐸=
= = 60 100 = 0.3961 ≈ 0.4
60 50 10 2 60
𝐹 𝑜−𝑢 50 10 − 1 −
− 100 60 40 100
60 40

= 𝟎. 𝟔𝟐𝟓
 40 10 40 10 30 40 30 10
𝑈 𝑓−𝑜 − − 60 40 − 1 −
= = 100 60 = 0.4 𝐸𝑈 = 100 = 0.75 𝐸𝑂 = 100 40 60
𝐹 𝑢−𝑜 30 10 30 10 40 10 30 40
40 − 60 − − 1−
40 60 100 60 40 100
= 0.8333
𝐸𝑇 = 𝐸𝑈 𝑥 𝐸𝑂 = 0.75 𝑥 0.8333 = 𝟎. 𝟔𝟐𝟓