About the Cyclosim_Single Spreadsheet ...

Scope :
The Cyclosim_Single spreadsheet was designed to simulate the response of a hydrocyclone (or cluster of
hydrocyclones) of any given geometry, operating in open circuit under known inlet conditions.
Theoretical Framework :
The technical literature contains various Empirical Correlations, attempting to describe the response of a hydrocyclone
in front of a given set of operating conditions. Examples of these formulations are the work of T. C. Rao and A. J. Lynch
from Australia ("Modelling and Scale-up of Hydrocyclone Classifiers", XI Int. Min. Proc. Congress II, 1-25, 1975. Also in
the book Mineral Crushing and Grinding Circuits, Elsevier, New York, 1977), the research of L. R. Plitt in the USA ("A
Mathematical Model for the Hydrocyclone Classifier", CIM Bulletin, p.114, December 1976) and the correlations proposed
by CIMM in Chile (as reported by L. Gutirrez and J. E. Seplveda, Dimensionamiento y Optimizacin de Plantas
Concentradoras Mediante Tcnicas de Modelacin Matemtica, CIMM Special Publication, 1986). Being all very similar in
nature, the latter has been incorporated to Cyclosim_Single.
In all of the above formulations, the Partition or Classification Function of the cyclones (defined as the fractional weight
recovery to the cyclone underflow of any given size fraction in the feed; badly called Classification Efficiency) is
decomposed into two effects : a direct feed slurry short-circuit to the underflow and the ideal (or corrected) classification
of a hypothetical cyclone with no short-circuit at all, in such a way that :
Ei = Bpf + (1 - Bpf ) Eic
where,
Ei
E ic
Bpf

= actual cyclone classification efficiency (fractional partition) for particles of size d i.

= corrected cyclone classification efficiency for particles of size d i, excluding the feed slurry short
circuit.
= fraction of the feed slurry that short-circuits the cyclone directly to the underflow.

The CIMM Model - essentially a variation of Plitt's Model - consists of the following 5 empirical correlations derived back
in 1983, from a fairly extensive experimental program under a wide range of cyclone geometries and operating conditions
:
Correlation 1 : Cyclone Feed Pressure
Q1.46 exp( -7.63+ 10.79 2 )
H = a1

______________________________________________

(DC)0.20 h0.15 (DI)0.51 (DO)1.65 (DU)0.53

where,
H
Q

= cyclone feed pressure, expressed in equivalent ft of feed slurry.

= volumetric cyclone feedrate, m 3/hr.
= fraction of solids in the cyclone feed, by volume.

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Moly-Cop Tools / 267722668.xls

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DC
h
DI
DO
DU

= cyclone diameter, in.

= cyclone free height, defined as the distance from the bottom of the vortex finder down to the top
of the apex, in.
= cyclone feed inlet diameter (circle area equivalent if the inlet is rectangular), in.
= cyclone vortex finder diameter, in.
= cyclone apex diameter, in.

and a1 is an application dependent constant to be determined from at least one set of actual plant data using
Spreadsheets Cyclobal_Single or Ballbal_Direct or Ballbal_Reverse, depending on the available data.
Correlation 2 : Corrected Cut Size, d50c.
The corrected cut size d50c is defined as that particular particle size that would be split on a 50:50 weight ratio between the
overflow and underflow streams, based on the corrected efficiency curve :
(DC)0.44 (DI)0.58 (DO)1.91 exp( 11.12 )
d

c
50

= a2

_______________________________________________

(DU)0.80 h0.37 Q0.44 ( s - 1 )0.5

where a2 is also an application dependent constant to be determined in a similar fashion as a 1.

Correlation 3 : Flow Split.
Q

S =

u
______

Qo

h0.19 (DU/DO)2.64 exp( -4.338.77 2 )

= a3

_________________________________________________

H0.54 (DC)0.38

where the flow split S (also referred to as the "wet" circulating load) is the ratio of the underflow volumetric flowrate to the
overflow flowrate of slurry. Again a3 is to be determined as a1 and a2.
Correlation 4 : Corrected Classification Efficiency.
Eic = 1 - exp [ - 0.693 (di/d50c)m ]
where the so called Plitt's Parameter m, has been correlated as follows,
m = exp [ a4 - 1.58 S/(S+1) ] [ (DC)2 h / Q ]0.15
and a4 is to be determined as a1, a2 and a3.
Correlation 5 : Slurry Short-Circuit.
The CIMM model contributed a 5th correlation relating (and so differentiating) the fractional slurry by-pass to the
underflow (Bpf) with the water by-pass (Bpw), through a direct proportionality expression :
Bpf = Bpw

Moly-Cop Tools / 267722668.xls

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where is the 5th application dependent constant, like the previous a 1, a2, a3 and a4 and where the water by-pass Bpw
may be obtained from :
S/(S+1) - R

Bpw =

c
s
____________________________

1 - [ 1 - Rsc)]

with Rsc - the hypothetical total underflow weight recovery of solids if the actual cyclone efficiency was to be the corrected
efficiency - given by :
n
R

c
s

fi Eic

i=1
and fi represents the weight fraction of particles of size d i in the cyclone feed stream.
The computation algorithm involves the direct evaluation of the first 4 correlations for H, d 50c, S and m to calculate the
corrected partition curve Eic for every particle size di. Then proceeds with the calculation of Rsc to obtain Bpf, Bpw and
finally, the desired actual partition function Ei for every particle size di. After these preliminary steps, the computation of
the detailed mass balance around the cyclones is fairly straight forward.
Data Input :
All data required by the model must be defined in each corresponding unprotected white background cell of the here
attached Data_File worksheet. Gray background cells contain the results of the corresponding formulas there defined
and are protected to avoid any accidental editing.
Simulation results are summarized in the Reports worksheet.
New Moly-Cop Tools users are invited to explore the brief comments inserted in each relevant cell, rendering the whole
utilization of the worksheets self-explanatory.

Moly-Cop Tools / 267722668.xls

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Moly-Cop Tools

TM

(Version 2.0)
CYCLOSIM
Simulation N

Remarks

Base Case Example

# of
Cyclones
10

Diameter
20.00

Cyclones Geometry, inches

Height
Inlet
Vortex
75.00
3.50
7.50

Operating Conditions :

Ore Density, ton/m3

Apex
3.67
2.80

Cyclone Feed Conditions

Slurry
Flow
Density
ton/hr
m3/hr
ton/m3
2609.01
1565.75
1.666

% Solids
(by volume)
37.02

% Solids
(by weight)
62.20

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse)

a1
a2
a3
a4
9.680
1.401
54.964
0.523
0.950
9.680
1.401
54.964
0.523
0.950

Bp (coarse)
0.050
0.000

Default Values

Dry Tons
ton/hr
1622.84

Water
m3/hr
986.16

Feed Size Distribution :

i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

Mesh
1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
-400

Opening
25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0

Mid-Size
30206
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19
Total

Moly-Cop Tools / 267722668.xls

ton/hr
0.00
0.00
18.17
41.49
40.76
37.01
38.53
44.14
51.21
66.98
78.83
100.61
122.86
142.11
143.62
125.60
98.97
73.25
53.99
38.98
305.76

% Ret
0.00
0.00
1.12
2.56
2.51
2.28
2.37
2.72
3.16
4.13
4.86
6.20
7.57
8.76
8.85
7.74
6.10
4.51
3.33
2.40
18.84

1622.84

100.00

% Pass
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84
0.00

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Moly-Cop Tools

TM

(Version 2.0)

Sample N

CYCLOSIM
Hydrocyclone Simulator
Remarks :

Base Case Example

Number of Cyclones :
Cyclone Dimensions, in :
Diameter
Height
Inlet
Vortex
Apex
Ore Density, ton/m3

Mesh

Opening

1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
-400

25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0

D80, microns
Ore, ton/hr
Water, m3/hr
Slurry, ton/hr
Slurry, m3/hr
Slurry Dens., ton/m3
% Solids (by volume)
% Solids (by weight)

Moly-Cop Tools / 267722668.xls

10

Operating Conditions :
Feed Flowrate, m3/hr
Pressure, psi
D50 (corr.), microns
Water By-Pass, %
Solids By-Pass, %
Plitt's Parameter
Circulating Load, %

20.00
75.00
3.50
7.50
3.67
2.80

Mid-Size
30206
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19

Size Distributions, % Passing

Feed
U'flow
O'flow
100.00
100.00
98.88
96.32
93.81
91.53
89.16
86.44
83.28
79.16
74.30
68.10
60.53
51.77
42.92
35.18
29.08
24.57
21.24
18.84

100.00
100.00
98.53
95.17
91.87
88.88
85.76
82.18
78.04
72.62
66.24
58.10
48.31
37.66
28.17
21.12
16.41
13.37
11.34
9.97

100.00
100.00
99.80
99.34
98.88
98.47
98.04
97.55
96.98
96.23
95.36
94.22
92.45
88.64
81.46
71.91
62.19
53.83
47.12
42.02

1273

1990

201.6

1622.8
986.2
2609.0
1565.7
1.666
37.0
62.2

1173.6
386.3
1559.9
805.4
1.937
52.0
75.2

449.2
599.9
1049.1
760.3
1.380
21.1
42.8

Page 6

1565.7
8.0
179.8
39.2
37.2
1.62
261

Classifier Efficiency
Actual Corrected
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.949
0.935
0.879
0.776
0.658
0.559
0.488
0.441
0.413
0.383

1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.998
0.975
0.878
0.698
0.495
0.323
0.200
0.119
0.071
0.018

Classifier Constants
a1
9.680
a2
1.401
a3
54.964
a4
0.523

0.950
Bpc
0.05

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Cyclones Geometry, inches

Diameter
20.0

Height
75.0

Inlet
3.50

Vortex
7.50

Apex
3.67

(by volume)
0.370

ton/hr
162.28

m3/hr
98.62

Classifier Constants : (from Cyclobal_Single, Ballbal_Direct or Ballbal_Reverse)

a1
a2
a3
a4
9.680
1.401
54.964
0.523

Operating Conditions :
ton/m3
156.57

2.80

0.950

Calculations
Correlation 1. Cyclone Feed Pressure, ft.
H
11.05621
Correlation 2. Corrected Cut Size, microns.
d50c
179.809
Correlation 3. Slurry Split.
S
1.108145
Correlation 4. Classification Efficiency.
Rsc

Bpw

Tyler
Mesh

Opening
micr.

Bpf

m (Plitt)
1.61731006 0.607512 0.39170013 0.37211513
Fraction
#

di*
micr.

Water
Water
U'flow
% Sol.
O'flow
% Sol.
0.05 38.62795 75.23689 59.98818 42.81973

Bpc

Feed
ton

Ei
% Ret.

(corr)

Rsc,i
= fi Eic

Ei
(real)

Underflow
ton

% Ret.

Overflow
ton

% Ret.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

1.05
0.742
0.525
0.371
3
4
6
8
10
14
20
28
35
48
65
100
150
200
270
400
-400
TOTAL

25400
19050
12700
9500
6700
4750
3350
2360
1700
1180
850
600
425
300
212
150
106
75
53
38
0

30206
21997
15554
10984
7978
5641
3989
2812
2003
1416
1001
714
505
357
252
178
126
89
63
45
19

0.00
0.00
1.82
4.15
4.08
3.70
3.85
4.41
5.12
6.70
7.88
10.06
12.29
14.21
14.36
12.56
9.90
7.32
5.40
3.90
30.58

0.00
0.00
1.12
2.56
2.51
2.28
2.37
2.72
3.16
4.13
4.86
6.20
7.57
8.76
8.85
7.74
6.10
4.51
3.33
2.40
18.84

162.28

100.00

1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
0.998
0.975
0.878
0.698
0.495
0.323
0.200
0.119
0.071
0.018

0.000
0.000
0.011
0.026
0.025
0.023
0.024
0.027
0.032
0.041
0.049
0.062
0.074
0.077
0.062
0.038
0.020
0.009
0.004
0.002
0.003
0.608

0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.950
0.949
0.935
0.879
0.776
0.658
0.559
0.488
0.441
0.413
0.383

0.00
0.00
1.73
3.94
3.87
3.52
3.66
4.19
4.86
6.36
7.49
9.55
11.49
12.50
11.14
8.27
5.53
3.57
2.38
1.61
11.70

117.36
Circulating Load :

0.00
0.00
1.47
3.36
3.30
3.00
3.12
3.57
4.15
5.42
6.38
8.14
9.79
10.65
9.49
7.05
4.71
3.04
2.03
1.37
9.97

0.00
0.00
0.09
0.21
0.20
0.19
0.19
0.22
0.26
0.33
0.39
0.51
0.79
1.71
3.22
4.29
4.37
3.75
3.02
2.29
18.88

0.00
0.00
0.20
0.46
0.45
0.41
0.43
0.49
0.57
0.75
0.88
1.14
1.77
3.82
7.18
9.55
9.72
8.36
6.72
5.09
42.02

100.00

44.92
2.61

100.00