Problem 1 A two stage grinding circuit using a rod mill in open circuit and ball mill in closed circuit with a hydrocyclone classifier is used to grind 100 tons/br of ore (sp. gr. 3.0). =a, ‘Sump Pump Underfiow The circuit is sampled and analysed for —200 mesh material and percent solids. Results of tests for samples ‘% —200mesh % solids Rod mill discharge 5 75.18 Ball mill discharge 20 78.33 Cyclone overflow 30 40.00 ‘Cyclone underflow 15 20.00 (i) Carryout a material balance and calculate the tons/br of dilution water added to the sump (ii) Calculate the flowrates of slurry, solids and water of all streams and specific gravities of all streams and illustrate the material balance of the whole circuitLet F = Flow rate of feed solids to hydrocyclone P = Flow rate of overflow solids from hydrocyclone low rate of solids fed to rod mill low rate of underflow solids from hydrocyclone u Solids balance over hydrocyclone F=P+U = F=100+U —200mesh material balance over hydrocyclone FE=Pp-+Uu = (100+ U)20=100 x 304U x15 > U=200tons/he; F=300tons/he Slurry balance over hydrocyclone Flow rate of slurry fed to hydrocyclone =Flow rate of hydrocylone overflow slurry + Flowrate of hydrocyclone underflowslurry Fraction of solids in overflow slurry 200 * Fraction of solids in underflow slurry 100 200 pan * gag ~250+ 250-500 => Fraction of solids in feed slurry to hydrocyclo Flow rate of slurry fed to ball mill = Flow rate of slurry discharged from rod mill + Flow rate of hydrocyclone underflow slurry 100 ‘Fraction of solids in rod mill slurry 200 * Fraction of solids in underflow slurry ao + a 133 + 250 =383tons/hr Flow rate of slurry discharged from ball mill Dilution water to be added to the sump. = Flow rate of slurry fed to hydrocyclone —Flow rate of slurry discharged fom ball mill = 500 ~383=117 tonshe Flow rate of solids in ball mill feed slurry =Flow rate of solids in rod mill discharge slurry + Flow rate of solids in hydrocyclone underflow slurry = 100-+ 200 =300tons/he% solids in ball mill feed slurry % solids in ball mill discharge slurry = 78.33%, Let the densities of slurries of rodmill feed and/(or) discharge, ball mill feed andi/(or) discharge, hydrocyclone feed, overflow and underflow be pc, Pxbs ‘ns Pato ad Pats By using equation #4 1—C# — | a these density values are calculated Pe asfollow: 0.2482 iS T 02167, T 040 ae T = > 36 gm/em? 020 meee Specific gravities of slurries of rodmill feed andi(or) discharge, ball mill feed and/(or) discharge, hydrocyclone feed, overflow and underflow are 2.00, 2.09, 1.67, 1.36 and 2.14 respectively. ‘Complete material balance for the circuit is illustrated in Fig, 18.1.1.1. GENS Bo x00 ‘m0 t200 ‘lary TPH %=200 mean 130 “5 Saute Ted 5 Sona = 3a Seth (WamrTE _ Spgreteum srsen [a 09) rs {J Hrcrocyctone 400 7330 38 3a 3500 ‘0 1800Problem 2 A two stage grinding circuit using a rod mill in open circuit with @ ball mill in closed circuit with a rake classifier is used to grind 40 tons per hour of ore (sp. gr. 3.0). Dilution Water ce (Fines) Rod Mill ‘| {= a ‘cme a Ball Mill The circuit is sampled and analyzed for percent ~100 microns material and percent solids. Creve sampling resus % solids Stream bywe CCireuit (Rod mil) Feed s 8 Rod Mil 20 80 CCassifir Sands (Ball Mill Feed) 20 75 Chassiier Overflow 75 333 Ball Mill Discharge 475 75 Using the above data carry out a material balance and calculate: (a) the tonslbr of dilution water added to the rake classifier (b) the percent circulating load in the ball mill circuit (c) the flow rates and specific gravities ofall streams and illustrate the material balance of the whole circuit Solution: In closed circuit grinding operation feed solids to the grinding circuit will be equal to the overflow solids from the rake classifier at steady state. ‘Therefore Tons of solids in the rake classifier overflow =40tonsIhr Let the sands discharged from the rake classifier be § tons/hr Balance of —100 microns material over the rake classifier 40 x 20 +5 x 47.5 =40 x 7548 x 20 > $= 80tonshhr Sands discharged from the rake classifier = 80 tons/hrDilution ratio of Rod mill discharge Dilution ratio of Ball mill discharge = Dilution ratio of rake classifier sands discharge = Dilution ratio of rake classifier fines discharge = Let the dilution water added to the rake classifier he W Water balance over the rake classifier 40 x 0.25 + W + 80 x 0,333 = 40 x 2.0 + 80 x 0.333 = W =70tons/hr (a) Dilution water added to the rake classifier = 70 tons/hr (b) Percent circulating load in the ball mill circuit 2 x 100=200% (c) Slurry flow rates Rod mill feed = Rod mill discharge = 40/0.80 = SOtons/he slurry Ball mill feed = Ball mill discharge = 80/0.75 = 106.7 tonsfhe slurry Rake classifier overflow = 40/0.333 = 120 tonshhr slurry Percent —100 micron material in feed stream to rake classifier _ 40 x 20 + 80 x 47.5 ~ 120) % solids in feed stream to rake classifier = 38.3% 100 = 52.9% Let the densities of slurries of rodmill feed and/(or) discharge, ball mill feed andJ(or) discharge and/(or) rake classifier underflow, rake classifier feed and rake classifier overflow be Pyirs Pups Pate ANA Pyig- By using equation S# 4 1 Cw — 1 31) chese density values are calculated Po Pu Pa as follows: 0.80 | 0.20 + = par =2.1gmjem> 1 Parozs 028 => paip=2.0gm/em? = pric=1.5gm/em? Specific gravities of slurries of rodmill feed and/(or) discharge, ball mill and/or) discharge and/or rake classifier underflow, rake classifier feed, ¢ overflow are 2.1, 2.0, 1.5 and 1.3 respectively. ‘Complete material balance for the circuit is illustrated in Fig. 18.1.2.1. izeNo tury TPH %—100mo0n Solas Te Solus Water TPH Serf tury Dilution Water 79ers. ie el 200 oY eed Feed: Rod Mill | lassifier Sands | |"Soa 720 ‘Sump Pump (Coarse)} | 27 20Problem 3: A copper flotation circuit is used to concentrate 100 tonsthr of ore. The ore contains chalcopyrite as valuable mineral with siliceous gangue. Specific gravity of chalcopyrite and gangue are 4.2 and 2.6 respectively. %Cu in chalcopyrite is 34.6%. Feed [Rougher ] 7\+Final Tailings Seer Dilution water [Cleaner |] a Final Concentrate Analyses of samples % solids xCu Circuit feed 3330 0.0 Rougher concentrate 50.00 13.89 Final concentrate 40.00 25.00 Cleaner tailings 862 5.00 Final tailings 31.10 O10 Using the above data, carry out a material balance and calculate the following: (a) the copper recovery in (i) the circuit (ii) the cleaners (iii) the roughers (6) the tons/hr of dilution water added to the cleaners (c) solids and slurry flowrates and specific gravities of all streams (d) Illustrate the material balance of whole circuitSolution: Let F = Flow rate of ore to the circuit = 100 tons/hr Cr Flow rate of rougher concentrate T Flow rate of final tailing, C = Flow rate of final concentrate Tc = Flow rate of cleaner tailing f =Assay value of ore feed c Assay value of final concentrate t Assay value of final tailing cr = Assay value of rougher concentrate tc = Assay value of cleaner tailing DR, = Dilution ratio of feed stream D. Dilution ratio of concentrate stream DR, = Dilution ratio of tailing stream Overall solids balance for the circuit F=C+T = 100=C+T 3 T=100-C Overall copper balance for the circuit Ff=Ce+Tt = 100x0.5=Cx2I5+TxO.1 = 100x05=Cx25+(100—C) x 0.1 = C=1.6tons/hr; T=98.4tons/hr Solids balance over cleaner Ce=C4+To = Cp=164+TeCopper balance over cleaner Creg=Ce+Tete > (16+ Tc)13.89=1.6 x 254+Te x5 = Tem Cz =3.6tons/hr 2 Copper recovery in the circuit = = x 100= os aa = x 100=80% Ce 6 x25 Cree “0 3B x 13.89 Copper recovery in cleaner = x 100=80% Caer Ff + Tete 3.6 x 13.89 = TOO x OSE IAS © 083.5% Copper recovery in rougher = Overall water balance F x DR, + Dilution water=C x DR-+T x DR, 66.7 po 60 68.9 > 100 x 5-5 + Dilution water = 1.6 x 75 > Dilution water = 20 tons/hr % chalcopyrite in feed = 5 x 100=1.45% % gangue in feed = 100-145 =98.55% Let the density ofthe feed solids = 100 _ 1.45 | 98.55 = etumlem® pe aa Oe P= ?61Em/cm 9% chalcopyrite in rougher concentrate = +82 x 100= 40.14% % gangue in rougher concentrate = 100 — 40.14 = 59.86% Let the density of the rougher concentrate solids = pre 100 40.14 | 59.86 oat. ? Pre = 3.07 gm/cm* % chalcopyrite in final concentrate =~ = x 100=72.25% % gangue in final concentrate. = 100~72.25=27.75% Let the density of the final concentrate solids = p- 100 72.25 , 27.75 TED TE FH 3.58 gm/em? % chalcopyrite in cleaner tailings = = x 100= 14.45% % gangue in cleaner tailings = 100 ~ 14.45 = 85.55%Let the density of the cleaner tailings solids = pcr 100 14.45 | 85.55 .75 g/cm? pa 42 * 26 % chalcopyrite in final alings = x 100=0.29% % gangue in final tailings» = 100 -0.29= 99.71% Let the density of the final tailings = p: 1000.29 , 99.71 my 4D oe = pas > py =2.60gm/cm3 Flow rate of slurry fed to the circuit. = = a 300.3 rons/hr 7 984 Flow rate of final tailing slurry = Tarr 316 Sons/he Flow rate of rougher concentrate slurry = PE =720ons/he Flow rate of final concentrate slurry = = a =4tons/hr a. 2 Flow rate of cleaner tailing slurry = ppgey = 23-2tons/he Complete material balance for the flotation circuit is illustrated in Fig. 18.1.3.1. LEGEND SuryTPH — % solids Solids TPH Spgr of stuny| Water TPH Feed 2003 3930) 363 34.10 1000 261 84 260 2003 2079 st : Rouwher Final T: Dilution 72 50.00) water 2 862 38 307] 2otpn 20 275 38 a2 Cleaner 40 4000 358 24 Final ConcentrateProblem 4 Zinc ore containing sphalerite (ZnS) and Silica (SiOz) is benefici- ated by froth flotation. The flotation circuit consists of Rougher, Scavenger and Cleaner bank of cells. The ore is fed to the rougher cells via conditioner at the rate of 1500 tons/day. Scavenger concentrate and cleaner tailings are re-fed to the rougher bank. Cleaner concentrate is the final concentrate and scavenger tailings is the final tailings. © Composition of each stream of flotation circuit. Weight % ZnS SiO, Feed 4.0 96.0 Rougher concentrate 40.0 60.0 Rougher tailings 1.0 9.0 Scavenger concentrate 50.0 50.0 Scavenger tailings 03 997 Cleaner concentrate 98.0 20 Cleaner tailings 200 80.0 Solid water ratio and contact time. Solid: Water (by weight) Contact time (sec) 450 700 600 450 Specific gravities of sphalerite and silica are 4.0 and 2.65 respectively, a) Illustrate the flotation circuit with neat diagram b) Determine the flow rates of all streams c) Determine the percentage yield d) Using flotation cell of 2.5 m' capacity, compute the number of flotation cells in each bank (rougher, scavenger, cleaner) e) What should be the capacity of the conditioner?Solution: ‘The flotation circuit diagram is shown in Fig. 18. Overall solids balance: FaC+T = 1500=C+T Overall CuS balance: Ff =Ce+Tt = x 9847 x03 > 6.81 tons/day = 443.19 tonsiday Feed F Conditioner Taiting R S Concentrate Concent aaner | Tana Pp Q Cleaner] H Scavenger ¢ T Final Final concentrate tailing gure 18.2.3 Flotation circult dlagram. Solids balance for Scavenger: Q=T+S + Q=1443.19+S CuS balance for Scavenger: Qq=Tt+Ss Q x 1= 1443.19 «0.348 x 50 = Q = 1463.81 tonsiday = $= 20.62 tons/day CHR + P=S6814R Ce+Rr 6.81 x 98+R x20 221.55 tons/day 64.74 tons/day Percent Yield= © x 100=. Be F [5004 * 100=92.8% Calculation of cells required Rougher feed contains F, R & S streams FUR S Volume of solids in Rougher = == +545 mn wm Water to solids ratio in rougher =3 Volume of water in F, R & S eee FR LS MERR+S) Cae Pw ‘Total volume of streams F, R & S=Density of solids in F = pr = rr) tonsim? Density of solids in R = p,= Density of solids in S = Total volume of streams F, R & S = 1500 164.74 | 20.62, 3(1500 + 164.74 + 20.62) ~ Teo" TR = 5678.17 m3 /day Volume of rougher = Volume of F, R & S x Contact time _ 5678.17 x 450 ~ 36005 24 Number of cells for rougher = 12 cells are required in rougher Qis the only feed to scavenger Density of solids in Q= py = pore —2 66 tomlin? Water to solids ratio in scavenger = 5 Volume of water in Q = QO SQ 1463.81, 5x 1463.8 ty ow 286 TO 7869.4 3600 x24 Total volume of Q= =7869.4m¥/day Volume of scavenger = 63.76m) Number of cells for scavenger = § =25.5 +26 s 26 cells are required in scavenger Pis the only feed to cleaner Density of solids in P= pp = pee = Mb tonsim? 50 * 265 Water to solid ratioin P= =7Volume of water in P = zp Pw Total volume of P= + ZP _ 224.55, 7221.55 _ 1693 95 milday me he 306 T 1623.25 x 600 5 Volume of cleaner = ee et = 11.27 m 27 Number of cells in cleaner = = =45e5 .. S cells are required in cleaner Total number of cells required = 12 +26+5=43 Calculation of conditioner volume Water to solid ratio in conditioner = 3 ‘Volume of water in conditioner = = = Volume of the pulp in conditioner = = + = ae 3x a“ = 5057.62 m3/day [As the contact time is 450 seconds, 5057.62 x 450 Capacity of the conditioner = =26.34m? 3600 x 24Problem 5 An ore having specific gravity of 3.5 is to be floated at the rate of 3000 tons/day with a pulp of 25% solids and flotation time of 10 minutes. Find the number of flotation machines of mechanical type required, if each machine has a capacity of 0.75 m with 70% effective capacity. Solution: Let the density of the ore and the pulp be p and pa. 1 _ Ge + 1eGe = 235 ,ors = py =1.217 tons/m? Pi Pw 35 Weight of solids ©=3000tons/day Weight of the pulp = 3000/0.25 = 12000tons/day _ 12000 x 1000 Taxco = 8333.33 kg/minute Volume of the pulp = 8333.33/1217 = 6.847 m?/minute Volume of the pulp in 10 minutes = 6.847 x 10=68.47m> Effective volume of cach machine = 0.75 x 0.7=0.525m? Number of machines required = 68.47/0,525 = 130.4 = 131