Mineral Industry

Mineral Processing 2 ME 365

Prof.Dr. Ahmed A.S. Seifelnassr

Professor of Mineral Processing
Dept. of Mining Engineering
Faculty of Petroleum and Mining Engineering
Suez University
Suez, Egypt
E-mail:[email protected]
 Lecture 3 - Slurry Streams calculations

Volumetric Flow rate

• From the grinding stage onward, most mineral processing operations are
carried out on slurry streams, the water and solids mixture being transported
through the circuit via pumps and pipelines.
• The water is acting as a transport medium, such that the weight of slurry
flowing through the plant is of little consequence.
• What is of importance is the volume of slurry flowing, as this will affect
residence times in unit processes.
• For the purposes of metallurgical accounting, the weight of dry solids
contained within the slurry is important.
• If the volumetric flowrate is not excessive, it can be measured by diverting
the stream of pulp into a suitable container for a measured period of time.
The ratio of volume collected to time gives the flowrate of pulp.
• This method is ideal for most laboratory and pilot scale operations, but is
impractical for large-scale operations where it is usually necessary to
measure the flowrate by online instrumentation.
• Volumetric flow rate is important in calculating retention times in processes.
For instance, if 120 m3h-1 of slurry is fed to a flotation conditioning tank of
volume 20 m3, then, on average, the retention time of particles in the tank
will be:
• Slurry Density and % Solids
• Slurry, or pulp, density is most easily measured in terms of weight of
pulp per unit volume. Typical units are kg m-3 and t m-3, the latter
having the same numerical value as specific gravity, which is
sometimes useful to remember. As before, on flow streams of
significant size, this is usually measured continuously by on-line
instrumentation.
• Small flow streams can be diverted into a container of known
volume, which is then weighed to give slurry density directly. This is
probably the most common method for routine assessment of plant
performance, and is facilitated by using a density can of known
volume which, when filled, is weighed on a specially graduated
balance giving direct reading of pulp density.
• The composition of a slurry is often quoted as the % solids by weight (100%
- % moisture), and can be determined by sampling the slurry, weighing,
drying and reweighing, and comparing wet and dry weights. This is time-
consuming, however, and most routine methods for computation of % solids
require knowledge of the density of the solids in the slurry.
• There are a number of methods used to measure this, each method having
pros and cons. For most purposes the use of a standard density bottle has
been found to be a cheap and, if used with care, accurate method. A 25- or
50-ml density bottle can be used, and the following procedure adopted:
• 1. Wash the density bottle with acetone to remove traces of grease.
• 2. Dry at about 40 OC.
• 3. After cooling, weigh the bottle and stopper on a precision analytical
balance, and record the weight, M 1.
• 4. Thoroughly dry the sample to remove all moisture.
• 5. Add about 5 - 10 g of sample to the bottle and reweigh. Record the weight,
M 2.
• 6. Add double distilled water to the bottle until half - full. If appreciable
“slimes” (minus 45 μm particles) are present in the sample, there may be a
problem in wetting the mineral surfaces. This may also occur with certain
hydrophobic mineral species, and can lead to false low density readings. The
effect may be reduced by adding one drop of wetting agent, which is
insufficient to significantly affect the density of water. For solids with extreme
wettability problems, an organic liquid such as toluene can be substituted for
water.
• 7. Place the density bottle in a desiccator to remove air entrained within the
sample. This stage is essential to prevent a low reading. Evacuate the vessel
for at least 2 min.
• 8. Remove the density bottle from the desiccator, and top up with double
distilled water (do not insert stopper at this stage).
• 9. When close to the balance, insert the stopper and allow it to fall into the
neck of the bottle under its own weight. Check that water has been displaced
through the stopper, and wipe off excess water from the bottle. Record the
weight, M 3.
• 10. Wash the sample out of the bottle.
• 11. Refill the bottle with double distilled water, and repeat procedure 9.
Record the weight, M 4.
• 12. Record the temperature of the water used, as temperature correction is
essential for accurate results.
• The density of the solids (s, kg m-3) is given by:

where Df =density of fluid used (kg m-3).

• Knowing the densities of the pulp and dry solids, the % solids by weight can
be calculated.
• Since pulp density is mass of slurry divided by volume of slurry.
Then for unit mass of slurry of x % solids by weight, the volume of solids is
x/100s and volume of water is (100 - x)/100 W, then (the 100’s compensating
for x in percent):
where x- % solids by weight, D = pulp density (kg/m3), s = density of solids
(kg/m3), w = density of water.
Assigning a value of 1000 kg/m 3 to the density of water, which is sufficiently
accurate for most purposes, Equation 3.5 gives:
Having measured the slurry volumetric flowrate (F, m3 h-1), the pulp density
(D, kg m-3), and the density of solids (s, kg m-3), the mass flowrate of slurry
can be calculated (FD, kg h-1), and, of more importance, the mass flowrate of
dry solids in the slurry (M, kg h-1):

or combining Equations 3.6 and 3.7:

• In some cases it is necessary to know the % solids by volume, a parameter,
for example, sometimes used in mathematical models of unit processes:

• 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:

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.
• Example 3.1
• A slurry stream containing quartz is diverted into a 1-1itre 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 quartz within the slurry.
• Solution
• The density of quartz is 2650kg/m3. Therefore, from Equation 3.6,

The volumetric flow rate, F = 1/7 L/S = 3600/7000 = 0.51 m3/h

M = FDX = 0.51 x1400x 45.9 /100 = 330.5 kg/h.
• Example 3.2
• A pump is fed by two slurry streams. One stream has a flow rate of 5.0 m3/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 3000kg/m3.)
• Solution
Slurry stream 1 has a flow rate of 5.0m3/h and contains 40% solids. Therefore,
from Equation 3.6:
• Therefore, from Equation 3.8, the mass flow rate of solids in slurry stream 1

Or, M= FDX/100 =5x1364x40 /100x1000 = 2,728 =2073 t/h

Slurry stream 2 has a flow rate of 3.4m-3/h and contains 55% solids.
From Equation 3.9, the pulp density of the stream = 1579kg/m-3.
Therefore, from Equation 3.8, 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 = 4.55 t/h
• Example 3.3
• A flotation plant treats 500 t 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
• The volumetric flow rate of solids in the slurry stream = mass flow rate/density
= 500 x 1000/2700 = 185.2m3/h
• The mass flow rate of water in the slurry stream = mass flow rate of solids x
dilution ratio
= 500 x (100 - 40)/40 =750t/h
• Therefore, volumetric flow rate of water = 750m3/h.
• Volumetric flow rate of slurry = 750 + 185.2 = 935.2m3/h.
• Therefore, for a nominal retention time of 5 min, the conditioning tank should
have a volume of 935.2 x 5/60 = 77.9m3.
• Note: Retention time = volume/flow rate of pulp.
• Example 3.4
Calculate the % solids content of the slurry pumped from the sump in
Example 3.2.
Solution
The mass flow rate of solids in slurry stream 1 is 2.73 t/h.
The slurry contains 40% solids, hence the mass flow rate of water
= 2.73 x 60/40 = 4.10 t/h
Similarly, the mass flow rate of water in slurry stream 2
= 1.82 x 45/55 = 1.49t/h
• Total slurry weight pumped
=2.73+4.10+ 1.82+ 1.49 = 10.14t/h
Therefore, % solids by weight
=4.55 x 100/10.14 = 44.9%
• Similarly, the mass flow rate of water in slurry

• stream 2

• = 1.82 • 45/55- 1.49t/h

• Total slurry weight pumped

• =2.73+4.10+ 1.82+ 1.49-10.14t/h

The use of size analyses in mass balancing
• Many units, such as hydrocyclones and gravity separators, produce a degree
of size separation and the particle size data can be used for mass balancing.
• The following example illustrates this concept.
• Example 3. 5
• In the circuit shown in Figure 3.22, the rod mill is fed at the rate of 20t/h of
dry solids (density 2900kg/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% + 250 µm - Ball mill discharge 4.9% + 250 µm-
Cyclone feed 13.8% + 250 µm
Calculate the volumetric flow rate of feed to the cyclone.
Solution
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
+250µm material gives: 13.8F = (26.9 x 20) + (F- 20) x 4.9
from which F = 49.4t/h.
Volumetric flow rate of solids = 49.4 x 1000/2900 = 17.0m3/h
• Volumetric flow rate of water =-49.4 x 65/35 =91.7m3/h
• Therefore, flow rate of feed to the cyclone = 17.0 + 91.7 = 108.7 m 3/h

•l discharge, and cyclone

• feed gave:
• Rod mill discharge 26.9% + 250 IxBall mill discharge 4.9% + 250 Ixm
• Cyclone feed 13.8% + 250 t
• 3. 7
 The use of Dilution Ratio in Mass Balancing
• Consider a hydrocyclone fed with a slurry containing f% solids by weight, and
producing two products- an underflow containing u% solids and an overflow
containing v% solids.
• If the weight of solids per unit time in the feed, underflow, and overflow are
F, U, and V respectively, then, providing the cyclone is operating under
equilibrium conditions“
•F=U+V 3.17
The dilution ratio of the feed slurry = (100- f )/ f = f'.
Similarly, the dilution ratio of the underflow = (100 - u)/u = u' and dilution ratio
of overflow = (100 - v)/v = v'. Since the weight of water entering the cyclone
must equal the weight leaving in the two products, the water balance is:
Ff'=Uu' + Vv‘ 3.18
• Combining Equations 3.17 and 3.18“ U/F = (f' - v')/(u' - v') 3.19
• Example 3.6
• A cyclone is fed at the rate of 20 t/h 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
• Dilution ratio of feed slurry=70/30 = 2.33
• Dilution ratio of underflow = 50/50 = 1.00
• Dilution ratio of overflow = 85/15 = 5.67
• A material balance on the cyclone gives“ 20 = U+V
• where U = tons of dry solids per hour in underflow; V = tons of dry solids per hour
in overflow.
• Since the weight of water entering the cyclone equals the weight of water leaving:
• 20 x 2.33 = 1.00U + 5.67V, or 46.6 = U + 5.67(20- U)
• which gives U = 14.3 t/h
Example. 7
A laboratory hydro cyclone is feed with a slurry of quartz (density 2650 kg/m3)
at pulp density of 1130 kg/m3, The under flow has a pulp density of 1280
kg/m3 and over flow 1040 kg/m3 , A 2˗ liter sample of under flow was taken in
3.1 sec , Calculate the mass flow rate of feed to the cyclone .
Solution •
• solids content of feed (Equation 3.11)
100x s(D−1000)
•X=
𝐷𝐷(𝑆𝑆−1000)
100×2650×130
• Solids content of feed = =18.5%
1130×1650
• Similarly % solids in under flow = 35.1%
• % solids in over flow = 6.2%
• Therefore, dilution ratio of feed, under flow and over flow are 4.4, 1.8 and
15.1 respectively.
• Volumetric flow rate of under flow = 2/3.1 liters/sec
2×3600
F =
3.1×1000
= 2.32 m3/h
• Therefore, mass flow rate of under flow (M=FDX/100)
35.1
=2.32×1280× =1.04t/h
100
• Therefore, from a water balance on the cyclone feed:
• 4.4 F = 1.04×1.8 + (F-1.04) ×15.1, Which gives mass flow rate (F) =1.29t/h
Water requirements, the value of circulating loads.
• Example 3.8
• The flowsheet shown in Figure below, illustrates a conventional closed circuit
grinding operation.

• .
• The cyclone overflow line is instrumented with a magnetic flowmeter 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
• A water balance on the cyclone gives
67𝐹𝐹 85 35𝑈𝑈
• = × 25 +
33 15 65
• Where F= cyclone feed (dry t/h)
• U=cyclone under flow (dry t/h)
• The mass flow rate of feed from the ore bin =25 t/h
(since input to circuit =output )
67 85 35𝑈𝑈
• Therefore, F=25+U And (25+U) =25× +
33 15 65
• From which U=61.0 dry t/h
• The circulating load is therefore 61.0 t/h
• and the circulating ratio is 61.0 /25 =2.44 .
• The ball mill feed =ore from bin +circulating load
• Water in ball mill feed =25×5⁄95 +61.0×35⁄65 =34.2m3/h
• Water in cyclone feed = (25+61.0)×67⁄33 =174.6m3/h
• Therefore water requirement at cyclone feed =174.6-34.2 =140.4m3/h
• Example 3.9
• Calculate the circulating load in the grinding circuit shown in Figure below
and the amounts of water added to the rod mill and cyclone feed.
• Feed to rod mill = 55 t of dry ore per hour
• Rod mill discharge = 62% solids
• Cyclone feed = 48% solids
• Cyclone overflow = 31% solids
• Cyclone underflow = 74% solids
• Solution
• Since input to circuit = output, the cyclone overflow contains 55 t/h of solids.
A water balance on the cyclone gives:

• which gives U = 85.8 t/h.

• The circulating load ratio is thus 85.8/55 = 1.56.
• Water in rod mill discharge = 55 x 38/62 = 33.7t/h
• Therefore, water addition to rod mill is 33.7 m3/h
• Water in ball mill discharge = 85.8 x 26/74 = 30.1 t/h
• Water in cyclone feed = (55 + 85.8) x 52/48 = 152.5t/h
• Therefore, water requirement to cyclone feed
= 152.5 - (33.7 + 30.1) = 88.7 t/h = 88.7 m3/h