SELECTION OF PRIMARY CRUSHERS

Primary Criteria for selection is:

1 Type of crusher to be used is determined on the basis of rock/ore.
2 Size of crusher is determined on the basis of plant capacity

Primary Crushers:
1 Gyratory
2 Double Toggle Jaw Crusher
3 Single Toggle Jaw Crusher
4 High Speed Roll Crusher
5 Low Speed Sizer
6 Impactor
7 Hammer Mill
8 Feeder Breaker

Priliminary Selection based on Feed and Product Size and Reduction Ratio:

Crushing Gringing Fine

Coarse Intermediate Fine Grinding
~x80 mm >50 5 - 50 0.5 - 5 0.05 - 0.5 <0.05
~r80 3-6 4 - 10 5 - 10 10 - 50 >50

Typical Parameters and fields of application of comminution equipment

Comminuting Machine Principal effect(s) Particle Size, mm Throughput Energy

Feed Output T t/h N Kwh/t
A Jaw Crusher Pressure 150 - 1800 25 - 250 10 - 1000 0.2 - 0.7
B Gyratory Crusher Pressure 150 - 1800 25 - 250 35 - 3500 0.15 - 0.3
C Cone Crusher Pressure, Blows 25 - 250 5 - 40 10 - 600 0.4 - 2.2
D Smooth Rolls Pressure 5 - 75 3 - 15 3 - 150 0.7 - 1.1
E Toothed Rolls Shear, Blows, Rubbing 75 - 500 50 - 200 5 - 1000 0.15 - 0.4
F Impact Mill Impact, Blows 2 - 250 0.3 - 0 0.2 - 600 0.4 - 7
G Hammer Mill Blows, Impact, Shear 0.8 - 500 0.04 - 50 0.05 - 400 0.7 - 150
H Ball Race Rubbing, Pressure 5 - 40 0.2 - 5
I Ring Mill Squeeze, Rubbing, Blows 0.8 - 25 0.04 - 0.8 0.02 - 20 3.7 - 150
J Rod Mill Pressure, Rubbing, Blows 5 - 25 0.07 - 0.8 3 - 75 7 - 15
K Ball, Tube, AG Mills Blows, Rubbing 5 - 20 0.04 - 0.5 2 - 12 10 - 30
L Viberating Mill Blows, Rubbing 0.5 - 10 0.002 - 0.2
M Buhr Mill Rubbing, Shear 10 - 25 0.07 - 0.8 0.2 - 5 10 - 150
N Jet Mill Impact, Rubbing 0.15 - 15 .001-.03 0.1 - 10

Typical Data of Comminuting Machinery

Output Brittle Tough

s80 Hard Medium hard Soft
5 - 10 Mohs 2 - 5 Mohs 1 - 2 Mohs
50 mm A,B d A,B,E,G d G,R d S,R
50 - 5 mm A,B,C,D d A,B,C,D,E d G1 d S
F,G G,G1,F
5 - 0.5 mm D,F,H d G,F,G1,D d G1,K1,D1,F1 d G1,S,F1
J d,m F1,K1,H,J M d,m K1,M
J d, m P
500 - 50 µm N d G1,K1,N d G1,K1 d G1,K1
K,L,J d,m J,K,L d,m M,D1 d,m M
T,P
50 - 5 µm N d G1 d G1 d T
K2,L,J d,m K2,L,J d,m L d,m
0.5 µm L d,m G1 d G1 d
K2 m L d,m L d,m
K2,D1,O m O m

Range of Typical Mohs Hardness of Material Handled

Feed to Size Reduc 10 9 8 7 6
Product Size Ratio Diamond Sapphire Topaz Quartz Feldspar
106µm Jaw Crusher
Gyratory Crusher Rotary Impactor
105µm 5
Roll Crusher

104µm Pan Mill

Rod loaded Tumbling Mill(dry)

103µm Ball loaded Tumbling Mill(dry)

50 Vibration Mill(dry)

10 µm
2

10µm 500

Size Of Equipment:
If tph < 161.7 X (gape in metres)2 --------------Use a Jaw Crusher
Capacity Chart of Jaw Crusher:
JAW CRUSHERS
JAW CRUSHER CAPACITY
TPH
1236 1836 2136 2436 2540 3040

1 1/2 40

2 55 55 55
DISCHARGE SETTING (INCHES)

3 85 90 90 90 145

4 125 125 125 185 185

5 155 155 240 240

6 195 195 290 290

7 340 340

8 390 390

10

11

CAPACITY CHART OF GYRATORY CRUSHER:

A X B, Feed D Eccentric
Size Openiong Head Dia. Gyra Cntr. Shaft Throw Max.
Inch Inch per min. RPM Inch HP 31/2
42-70 HD 42 X 114 70 137 514 3
/4 200
1 250
11/8 270
11/4 300
42-70 XHD 42 X 114 70 137 514 3
/4 240
1 320
11/8 360
1 /4
1
400
48-75 HD 48 X 133 75 140 514 1 300
11/4 375
1 /8
3
410
1 /2
1
450
54-75 HD 54 X 144 75 140 514 1 300
11/4 375
1 /8
3
410
 11/2 450
54-80 HD 54 X 145 80 140 514 1 /4
1
400
1 /8
3
425
1 /2
1
460
1 /8
5
500
60-90 XHD 60 X 165 90 115 514 1 /8
3
550
1 /2
1
600
1 /8
5
650
1 /4
3
700
60-102 HD 60 X 174 102 115 514 1 /2
1
600
1 /8
5
650
1 /4
3
700
2 750
60-102 XHD 60 X 174 102 115 514 11/2 750
1 /8
5
800
1 /4
3
875
2 1000

Capacity of Crusher Q =
A

Technical Data for selection and sizing of crusher

A. Selection based on Impact Strength
1. Determination of Impact strength in foot lbs per inch ( C for average impact strength)
2. Determine the Compressive strength in lbs per square inch
3. Bond's Impact work index: Wiu = 2.69C/S WI=53.49 ICS/SG where ICS is Impact Crushing
where S is [Link] of material. SG is Specific Gravity of mater
C is average impact strength in foot lbs per inch.

Category Impact strength per inch Compressive Strength

 Foot lbs Joules/mm N-m/cm psi Kg/cm2
per inch

Very soft <8 0.013 < 0.13 < 10000 < 703.07
Soft 8 - 12 0.013-0.020 0.13 - 0.20 16500 1160.07
Medium 12 - 16 0.020-0.027 0.20 - 0.27 22000 1546.75
Hard 16 - 20 0.027-0.033 0.27 - 0.33 27500 1933.44
Very Hard 20 - 24 0.033-0.040 0.33 - 0.40 33000 2320.13
Extremely Hard > 24 > 0.040 > 0.40 > 33000 > 2320.13

B. Selection based on Abrasive Index

Pennsylvania Crusher Abrasive Index
The abrasive index of the ore to be crushed can be used as a guide in selecting the crusher

Material Tipical Abrasive Index Abrasive Index Range

Aluminum Oxide 14000 0 - 35000 Gy, DTJaw
Sandstone 13000 0 - 6000 Gy, DTJaw, STJaw, LS Sizer
Quartzite 11000 0 - 2000 Gy, DTJaw, STJaw, LS Sizer,
Gold Ore 8000 0 - 1000 Gy, DTJaw, STJaw, LS Sizer,
Granite 7000
High Silica Limestone 5000
Tungsten Ore 3000
Hematite 600
Limestone 500
Clay 25

C. Selection based on Clay Content D. Selection based on Underground Serv

SN Crusher Clay Content U/G Services: Must handle Blocky, Hard and
1 Gyratory Low Very Good But high space required
2 Double Toggle Jaw Crusher Low Excellent
3 Single Toggle Jaw Crusher Average Excellent
4 High Speed Roll Crusher No clay Can not used
5 Low Speed Sizer High Clay Excellent Low space, effortlessly handlle
6 Impactor No clay Can not used
7 Hammer Mill No clay Can not used
8 Feeder Breaker Average Very Good

SELECTION CHARTS FOR PRIMARY CRUSHERS:

Primary Crusher Selection by Capacity in MTPH
Crusher / mtph 1500 3000 6000 9000 12000
Gyratory ///////////////////////////////////////////////////////////////////////////////////////////////
Double Toggle Jaw Crusher ///////////////////
Single Toggle Jaw Crusher ///////////////////
High Speed Roll Crusher //////////////////////////////////
Low Speed Sizer ////////////////////////////////////////////////////////////////////////////////////////////////////
Impactor //////////////////////////////
Hammer Mill //////////////////////////////
Feeder Breaker ////////////////////////

Primary Crusher Selection by Abrasion Index

Crusher / Burbank 0 800 16000 24000 32000
Gyratory ///////////////////////////////////////////////////////////////////////////////////////////////
Double Toggle Jaw Crusher //////////////////////////////////////////////////////////////////////////////////////////////////
Single Toggle Jaw Crusher ////////////////////////////////////
Double Roll Crusher ////////////////////
Low Speed Sizer ////////////////////////////////////
Impactor //////////////////
Hammer Mill ////////////////////
Feeder Breaker ///////////////////

Primary Crusher Selection by Compressive Strength

Crusher / Mpa 0 100 200 300 400 500
Gyratory ///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
Double Toggle Jaw Crusher ///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
Single Toggle Jaw Crusher ///////////////////////////////////////////////////////////////////
Double Roll Crusher ///////////////////////////////
Low Speed Sizer ///////////////////////////////////////////////////////////////////
Impactor ///////////////////////////////////////////////////////////////////
Hammer Mill ///////////////////////////////////////////////////////////////////
Feeder Breaker ///////////////////////////////////////////////////////////////////

JAW CRUSHER
Design Consideration: Example : Model 2540 set = 6" G 635 mm

1. Angle between jaws = Angle of Nip < 2 X Angle of friction

Let f = 0.3 Angle of friction = 16.7 φ = Nip Angle = 33.40
Note: Normally a Nip angle of 24o is used.
A B
2 G G
G
 φ

s l s l s l

Relative Volume passed per throw in A - plane-jaw, B - convex-jaw design

Critical Speed at which free fall occures= ncrit = 66.4 X √ tan(φ)/l

3. Throw l = 0.06 X G0.85 Ex. l = 14.47 mm

4.a. Capacity T = 845 X L(s+l) = 845 X LG/r' = 845 Ls(1 + 1/p) = CLS Ex. T = 143.26

T = Capacity Tons/hour
L = Width , m
r = G/s
p = s/l

b. Capacity T = 1000(GL)1.1 tons/hour Ex. T = 617.49604

c. T = f . ρ . L . q . l . N . a . r Ex. T = 36.989167
where
T = short tons/hour
f = factor(Table 1)
ρ = Bulk density of product lb/ft3
L = width, inches
q = open side setting
l = =(q-t) length of stroke
N = number of strokes/minute
a = Nip angle factor (Table 2)
r = factor(Table 3)

5. Power Draw
a. N = 10Wi (1/√x - 1/√xo) KWh/T x,xo = 80% particle size Ex. N =

xo =
x=

b. N = K. C. A KWh/t

c. N = 1.2 LG N=KW LG = dm2

S

Suited Unsuited
For Rocks s-slippery
h, mh so, st h-hard
h, mh so, st mh-medium hard
h, mh so, st abr-abrasive
mh, f, abr s so-soft
fr h f-fibrous
abr st-sticky
non-abr,soabr fr-friable
mh
so, mh abr Note: 1 to 4T t/h of steam or 6 to 9 T t/h of compressed air.
abr so
abr
abr
so, f h, abr
mh, fr so, st

Tough D1-Roller Mill

F1-Impact Breaker(Scattered Disk type)
G1-Impact Mill
d H-Chilean Mill
 K1-Grate Mill
d K2-Tube Mill
M-Disc Pulveriser
d O-Colloid Mill
P-Polishing Machiner
m R-Saw
d S-Cutter
m T-Shredder
m d-dry
m m-moist

ess of Material Handled Sticky

5 4 3 2 1 Materials
Apatite Fluorspar Calcite Gypsum Talc

Rotary Impactor
AG Mill
Stamp Mill
Disc Mill
Pan Mill
Hammer Mill

Ring roll and Ring Ball s

Vibration Mill(dry)
 CAPACITY

Gape
3040 3648 4248

275

350

290 425 425

340 475 475

390 525 525

575 575

650 650
Throw
800
CSS
OSS

4 41/2 5 51 / 2 6 61/2 7 71/2 8 81/2

525 625 730 835 925 1020
700 830 975 1110 1230 1360
785 936 1100 1250 1385 1530
1040 1220 1390 1540 1700
430 525 625 730 835 925 1020
700 830 975 1110 1230 1360
785 936 1100 1250 1385 1530
1040 1220 1390 1540 1700
1175 1250 1330 1440 1565 1700 1840
1567 1660 1800 1955 2125 2300
1720 1880 1980 2150 2340 2530
1995 2160 2350 2550 2760
1300 1400 1510 1630 1775 1730
1750 1885 2040 2220 2410
1925 2075 2240 2440 2655
 2265 2445 2660 2895
1825 1950 2170 2420 2650 2900
2010 2145 2385 2660 2915 3190
2340 2605 2905 3180 3480
2535 2820 3145 3445 3770
1955 2130 2420 2660 2900
2130 2390 2640 2900 3160
2580 2860 3140 3425
2775 3080 3385 3635
3140 3500 3900 4270
3400 3790 4225 4625
4085 4550 4980
4665 5200 5695
3140 3500 3900 4270
3400 3790 4225 4625
4085 4550 4980
4665 5200 5695

Capacity of Crusher Q = (D-S)∏[Link](a.k.60n) m3/hr

D= Dia. Of outer head mantle at discharge point(m) 1.905
S= Open side setting (m) 0.1524
s= Throw (m) 0.0254
a= angle of nip 25
n= speed of crusher (RPM) 140
k= material constant between 1.5 -2.0 2
Q= 0.041126 m3/hr
tph = 67.44582

where ICS is Impact Crushing Strength of materials in Joules per millimeter

SG is Specific Gravity of materials

essive Strength
 Mpa
Equiv. Crusher Selection
< 68.95 -70 Mpa Gy, DTJaw, STJaw, LS Sizer, HS Roll, Feeder Breaker, Impactor, Hammer Mill
113.76 115 Mpa Gy, DTJaw, STJaw, LS Sizer, HS Roll, Feeder Breaker, Impactor, Hammer Mill
151.68 150 Mpa Gy, DTJaw, STJaw, LS Sizer, HS Roll, Feeder Breaker
189.61 190 Mpa Gy, DTJaw, STJaw, LS Sizer
227.53 230 Mpa Gy, DTJaw
> 227.53 +250 Mpa Gy, DTJaw

Crusher to be selected
Gy, DTJaw
Gy, DTJaw, STJaw, LS Sizer
Gy, DTJaw, STJaw, LS Sizer, HS Sizer
Gy, DTJaw, STJaw, LS Sizer, HS Roll, Feeder Breaker, Impactor, Hammer Mill

based on Underground Services E. Selection based on Mobile Crush

: Must handle Blocky, Hard and wet materials, steel in the form of drill steel & roof bolts All crushers may be used
But high space required

Low space, effortlessly handlle steel

Primary Crusher Selection by ROM Feed Size Primary Crusher Sele

Crusher / mm 500 1000 1500 2000 2500 Crusher / mm
Gyratory ///////////////////////////////////////////////////// Gyratory
D T Jaw Crusher ///////////////////////////////////////////////////// D T Jaw Crusher
S T Jaw Crusher ///////////////////////////////////////////////////// S T Jaw Crusher
Doble Roll Crusher ///////////////////////////////////////////////////// Doble Roll Crusher
Low Speed Sizer //////////////////////////////////////////////////////////////// Low Speed Sizer
Impactor ///////////////////////////////////////////////////// Impactor
 Hammer Mill ///////////////////////////////////////////////////////////////////////////////////////// Hammer Mill
Feeder Breaker ///////////////////////////////////////////////////// Feeder Breaker

Application of Primary Crusher for High Clay Materials Application of Primary Crush
Crusher / Perform Poor Fair Good Very GoodExcellent Crusher / Perform
Gyratory ///////////////// Gyratory
D T Jaw Crusher ///////////////// D T Jaw Crusher
S T Jaw Crusher ///////////////// S T Jaw Crusher
Doble Roll Crusher ///////////////// Doble Roll Crusher
Low Speed Sizer ///////////////// Low Speed Sizer
Impactor N/A Clay will Plug the Crusher Impactor
Hammer Mill N/A Clay will Plug the Crusher Hammer Mill
Feeder Breaker ///////////////// Feeder Breaker

Application of Primary Crusher for Mobile Plants

600 Crusher / Perform Poor Fair Good Very Good Excellent
////////////////////////////////////// Gyratory /////////////////
////////////////////////////////////// D T Jaw Crusher /////////////////
S T Jaw Crusher /////////////////
Doble Roll Crusher /////////////////
Low Speed Sizer /////////////////
Impactor /////////////////
Hammer Mill /////////////////
Feeder Breaker /////////////////

L 1016 mm s 152.4 mm

G
φ
l/tan(φ)

57.19842

tph

tph

0.354769 102.883 246.9192

571500
67225.31
Jaw Crusher
Gyr. Crusher
Rotory Impactors
AG Mill(Dry)
Stamp Mills
Roll Crusher
Disc Mills
Pan Mills(Dry)
Hammer Mill
Rod Loaded Tumbling Mill(Dry)
Ultra Rotor
Ring Roll & Ball Mill
Ball loaded Tumbling Mill(Dry)
Vibration Mill(dry)
Pan Mills
Sand Mills
Fluid Energy Mils
Colloid Mills

µm
Jaw Crusher
Gyr. Crusher
Rotory Impactors
AG Mill(Dry)
Stamp Mills
 Roll Crusher
Disc Mills
Pan Mills(Dry)
Hammer Mill
Rod Loaded Tumbling Mill(Dry)
Ultra Rotor

Ring Roll & Ball Mill

Ball loaded Tumbling Mill(Dry)

Vibration Mill(dry)

Pan Mills

Sand Mills

Fluid Energy Mils

Colloid Mills

Throw

9 10
3145
3430
3715
4000
4640 5400
5025 5850
5415 6300
6185 7200
4640 5400
5025 5850
5415 6300
6185 7200
tion based on Mobile Crushing Plants
ers may be used

Primary Crusher Selection by Product Size

100 200 300 400 500
/////////////////////////////////
//////////////////////////////////////////
//////////////////////////////////////////

/////////////////////////////////
//////////////////////////////////////////////////
 //////////////////////////////////////////////////
///////////////////////////////

cation of Primary Crusher for Underground Service

Poor Fair Good Very GoodExcellent
/////////////////
/////////////////
/////////////////
/////////////////
/////////////////
N/A
N/A
/////////////////
 Mohs Hardness of Material Handled
10 9 8 7 6 5 4 3 2 1
Jaw Crusher /////////////////////////////////////////////////////////
Gyr. Crusher /////////////////////////////////////////////////////////
Rotory Impactors //////////////////////////////////////////
AG Mill(Dry) ///////////////////////////////////
Stamp Mills ///////////////////////////////////////
Roll Crusher //////////////////////////////////////////////////
Disc Mills ////////////////////////////
Pan Mills(Dry) ///////////////////////////////////////
Hammer Mill /////////////////////
Rod Loaded Tumbling Mill(Dry) //////////////////////////////////////////////////////
Ultra Rotor /////////////
Ring Roll & Ball Mill ////////////////////////////
Ball loaded Tumbling Mill(Dry) /////////////////////////////////////////////////////////
Vibration Mill(dry) ///////////////////////////////////
Pan Mills /////////////
Sand Mills /////////////////////////
Fluid Energy Mils ////////////////////////
Colloid Mills /////////////

Range of Feed to Product Size

µm 10 105 104 103 102 10 0
6
0 0 0
Jaw Crusher //////////////////
Gyr. Crusher //////////////////
Rotory Impactors ///////////////
AG Mill(Dry) /////////////////////////
Stamp Mills ///////////
Roll Crusher ////////
Disc Mills ////////
Pan Mills(Dry) /////////////////////
Hammer Mill //////
Rod Loaded Tumbling Mill(Dry) //////
Ultra Rotor ///////////////////////

Ring Roll & Ball Mill ///////////////

Ball loaded Tumbling Mill(Dry) ///////////////////

Vibration Mill(dry) ///////////////////

Pan Mills /////////////////

Sand Mills ////////////

Fluid Energy Mils ////////////

Colloid Mills ///////////

Vibrating Screen Capacity Calculation:
Screen Size: Width 2.45 m Length 5.47 m

F= 11.39 m2

Deck of Screen: Top Deck 11.39 m2 Bottom Deck 7.97 m2

Screen Mesh= 40 mm

Q=Fxqxδxkxlxmxnxoxp t/h
SET Value
F= Effective area of Screen 11.39 m2
q= Specific Capacity per m2 of screen surface 38.1 20.76 m3/hr
δ= Bulk density of material 1.8 1.8 t/m3
k= Half size co-efficient 40 1
l= Coarse grain co-efficient 25 1
m= Screening Efficiency 80 1.3
n= Grain shape factor Mineral 1
o= moisture content factor (Screen Mesh<25mm) Dry 1
o= moisture content factor (Screen Mesh>25mm) Dry 0.9
p= Screening Method (Screen Mesh<25mm) Dry 1
p= Screening Method (Screen Mesh>25mm) Any 1

Q= 498.08 t/h

Area Calculation if the Capacity of Screen is Given

C= 2000 F= 45.74 width = 4.28 Length =

%
% grain of <half of oversize Screening
screen mesh size in K grains in l Efficiency m
feed feed (%)
0 0.2 10 0.94 40 2.3
10 0.4 20 0.97 50 2.1
20 0.6 25 1 60 1.9
30 0.8 30 1.03 70 1.6
40 1 40 1.09 80 1.3
50 1.2 50 1.18 90 1
60 1.4 60 1.32 92 0.9
70 1.6 70 1.55 94 0.8
80 1.8 80 2 96 0.6
90 2 90 3.36 98 0.4
Grate area calculation:
IF Then
Q = Hourly capacity of screen t/h F=Grate area of screen, m2
a=Grate opening mm F = Q / 2.4 X a m2

Size Selection of Screens (MULAR)

Screena are selected by using the following basic equations:

A= Required Screen Area= Tons per hour undersize in feed / C x ρ x F x E x S x D x O x W

Where
A= m2
C= Standard Capacity STPH/0.092 m2
ρ= Bulk density ratio = Bulk density of material kg/m3
1602
F,E,S,D,O,W = Correction factores

Slection of area of screen:

Ex. Given
Size distribution of Feed to screen

300 1.5 Selection of screen of aperature = 40

200 15
100 28 TPH undersize = 555
50 22
25 10
15 5
8 13
0 5.5
100
Feed quantity 1000 tph

Calculation of FESDOW:

i. Fine Factor F Feed Material < 1/2 the size of screen opening. 0.3
ii. Efficiency Factor E 0.8
[Link] Factor S Screen of non square opening Square and Slight rectangular Openings
iv. Deck Factor D Top
v. Open area correction O at specified screen opening of std. 38.1 mm 64
vi. Wet Screening Factor W +2"

Standard Capacity C = 3.4 for 38.1 mm or for

Bulk Density(Kg/m3) 2.2 2200

Area of Screen 703.00 m2

So minimum area required for Screen 773.30 m2 width = 17.59 Length =

% Factor
Fines Efficiency Sq. OPG. Size STPH
F E inch mm
0% 0.44 0.00 0 0.00
10% 0.55 0.25 6.35 1.08
20% 0.70 0.50 12.7 1.70
30% 0.80 0.75 19.05 2.20
40% 1.00 1.00 25.4 2.65
50% 1.20 1.25 31.75 3.05
60% 1.40 1.50 38.1 3.40
70% 1.80 2.25 1.75 44.45 3.75
80% 2.20 1.75 2.00 50.8 4.02
85% 2.50 1.50 2.25 57.15 4.25
90% 3.00 1.25 2.50 63.5 4.42
 95% 3.75 1.00

SIZE OPENING
W
Deck Deck Factor (Square)
D
Top 1.00 1/32" or less 1.25
2nd 0.90 1/16" 3.00
3rd 0.80 1/8" & 3/16" 3.50
5/16" 3.00
3/8" 2.50
1/2" 1.75
3/4" 1.35
1" 1.25
+2" 1.00
10.69 W/L Ratio= 2.5

Moisture
Content
Shape of n of o Screening p
grains material Method
Mineral 1 Screen mesh < 25 mm Screen mesh < 25 mm
Sands 1.25 Dry 1 Dry 1
Coal 1.5 Moist 0.75 0.85 Wet(Sprayi 1.25
Clotting 0.2 0.6

Screen mesh > 25 mm Screen mesh > 25 mm

Dry 0.9 Any 1
Wet 1
ExSxDxOxW

Value
0.8
 1.75
1
1
1 Open Area of deck used at 38.1 mm 64
1

40 3.61

43.97 W/L Ratio= 2.5

%OA
%
0
42
53
56
58
64
64
64
67
70
69
 Length/Width Ratio
Typical Deck Preparatios S
Less Than Greater
Square and Slight rectangular Openings 2 1 1.00
Rectangular Openings Ton-Cap 4 2 1.15
Slotted Openings Ty-Rod 25 4 1.20
Parallel Rod Decks(Slot || Flow) - 25 1.40
Parallel Rod Decks(Slot Ļ Flow) - 25 1.30
en mesh < 25 mm

1.4

en mesh > 25 mm
Spiral Classifier Selection:
Two types 1 Non submerged spiral for producing coarse overflows(coarse than 0.1mm)
2 Submerged spiral and used for thr product of 0.2-0mm size

Overflow capacities of single spiral classifier with non submerged spiral(Ore Specific gravity of 2.65 t/m 3)

Spiral Dia Overflow capacity tonnes/24hr at nominal overflow size

mm 0.6 0.42 0.3 0.2 0.15 0.1
500 68 62 54 46 32 20
750 140 127 110 95 65 43
1000 235 215 190 160 110 75
1200 330 300 260 220 155 100
1500 510 460 400 345 235 155
2000 880 795 690 595 410 270
2400 1245 1130 990 850 580 380
3000 1910 1750 1520 1300 884 590

Double Spiral double the above capacities.

Different Specific Density will carry a correction factor as per given table:
Correction factors for different specific densitys
Specic correction
Density factor
2.00 0.67
2.50 0.92
2.65 1.00
3.00 1.17
3.50 1.42
4.00 1.70

Alternate Method of O/F Capacity Calculation:

Overflow Capacity may be calculated by following formulae:

a Spiral Dia < 1000 mm Non immersed type

Q=Cxmxaxb(94D2+16D)
Spiral Dia > 1000 mm Non immersed type

Q=Cxmxaxb(65D2+74D-27.5)
a Spiral Dia < 1000 mm Immersed type

Q=Cxmxaxb(75D2+10D)
 Spiral Dia > 1000 mm Immersed type

Q=Cxmxaxb(50D2+50D-18)
Where
Q= Overflow solid content capacity t/day
m= Numbers of spirals in a classifier
D= Spiral diameter, m
a,b,c = correction factor for overflow size & material density & overflow density

Correction factor for overflow size in spiral classifier capacity Correction factor for density of material to be classifie
liquid to solid
Material
Max. o/f ratio(ore
a density, b
size mm density=2.7g/c
g/m3
m3)
0.40 1.80 1.95 2.7 1.00
0.30 2.00 1.70 3.0 1.15
0.20 2.33 1.46 3.3 1.30
0.15 4.00 1.00 3.5 1.40
0.10 4.50 0.66 4.0 1.65
4.5 1.90

Above formulae are true for ores of 2.7 g/cm3 density and at definite overflow dilutions(liquid to solid ratio) called reference dilu

Rref = R2.7 X (2.7 / δ)

Rref = Reference dilution for ore of δ density

R2.7 = Reference dilution for ore of 2.7 g/cm3 density

If the calculated dilution Rcal(Actual dilution) differ with the reference dilution Rref then the capacity should be corrected by a c

Where
C = Rcal/Rref

Spiral Underflow Capacity is calculated from the formula:

Q = 135 X m X b X n X D3

Q = Underflow capacity, t/day

n = Spiral speed, rpm
 density of material to be classified Correction factor in the capacity formula of spiral classifier on basis of overflow depending upo

Ratio of calculated dilution

to reference dilution i.e. c
Rcal/Rref

0.6 0.70
0.8 0.85
1.0 1.00
1.2 1.10
1.4 1.20
1.7 1.25
2.0 1.20
3.0 1.00
4.0 0.85
5.0 0.70

to solid ratio) called reference dilution. Eference dilution for ores of other density can be given by:

apacity should be corrected by a correction factor 'c' given above table.

on basis of overflow depending upon density of overflow
Thickener Capacity Calculation:
F = (R1 - R2) / (86.4 x V x K)
F= Required Settling surface per 1 tonne of thickener daily capacity, m2/t/day

R1= Weight liquid to solid ratio in the pulp

R2= Weight liquid to solid ratio in the thickened product
K= coefficient = 0.7 - 0.8
V= Velocity of falling in water of most coarse solid particles(up to 4-5 micron), discharging with overflow, mm

V = 545 x (δ - 1) x d2
δ Particle density g/cm3
d Particle diameter mm

Example
Iron Ore DNM
δ 4.35
d 0.15

v 41.07938

F 0.003421
tpd 16200 47520
F 55.42406 m2 162.5772
dia 8.412128 14.39669

Calculation of Tailing Thickener

Basic Data Megha-conMegha-tail

1 Solids Design tph - W 675 (Dry solid input) 190 124
2 Feed % solids by wt 31 29 8.4
3 Underflow %solid by wt 60 67 40
4 Solids SG 4.35 4.5 3
5 Feed Slurry SG - S 1.314 1.291 1.059
6 Settling rate in m/h - R 0.91 3 1

Using Formula of Coe Clevenger Method

Area = ( F - D ) W / R * S

F 2.23 2.45 10.90

D 0.666667 0.492537 1.5

R 0.91 3 1

S 1.314 1.291 1.059

Area in m2 880.4059 95.92535 1100.884

Design Margin 50% 25% 25%

Area required in m2 1320.609 119.9067 1376.105

Dia of Thickener in m 41.0055 12.35597 41.85823

Select 43 14 44
discharging with overflow, mm/sec

354

Settling area 0.229 Sq. m/t

28.396

Tailings
0.092 0.086 0.076 0.183
167.2 188.48 228.16 213.28 188.48 453.84
212.8857 239.9802 290.5023 271.5565 239.9802 577.847
14.5906 15.49129 17.04413 16.47897 15.49129 24.03845

20.45295 19.77477 18.58955 28.84614

Conc
0.028 0.046 0.0342
106.4 174.8 129.96
135.4727 222.5623 165.4702
11.63927 14.91852 12.86352

13.96713 17.90223 15.43623

 PROCESS DESIGN CRITERIA
Client Name: SAIL Project Design Criteria
Project Name: Feasability Report for Raoghat Iron Ore Project
Work Item Number: QhCU

MECON LIMITED_____________________________________________________________________________________
RM & Mining Section

2. PROCESS DESIGN CRITERIA

2.1 Process Description
2.2 Design Criteria
The following design criteria establishes the design parameters that are to be followed in project design and execution.
The criteria have been compiled from the various sources listed below. The sourse for a particular criterian is identified
per the code in the following list of sources.

SAIL Steel Authority of India Limited IND Industrial Practice

DER Derived or calculated result PL Process Licensor
MEC MECON Ltd. VEN Vendor Information
TL Testing Lab

UNIT VALUE SOURCE COMMENTS

2.3 Ore Characteristics
Mine Operations:
-Ore production rate tonnes/y 14000000
tonnes/d 38356
-Operating days per year days 300 MEC
-Mines life years 25
Schedule: Shift per day 3 SAIL
Hours per shift hours 8 SAIL
Plant Performance:
-Availability % 90 SAIL
-Daily Throughput(Design) tonnes/d 42618 DER
-Specific Gravity: 4.2
-Average, Design 4.5 MEC In situ, Wax emmersions
Use for crushing and Milling
4.5 Pychnometer, use for the rest of process
-Bulk Density tonnes/m3 2.6 MEC Based on in-situ SG

ROM:- Ore Size mm 1200 SAIL

-Moisture Content %w/w nom.3/max.5SAIL
-angle of repose degree 37 MEC
-draw down angle degree 60 MEC
Low Impact Crushing Index TL
Autogenous Work Index kWh/t TBD MEC RDCIS to specify
Bond Work Index(Rod Mill) kWh/t 14 TL RDCIS to specify
Bond Work Index(Ball Mill) kWh/t 16 TL RDCIS to specify
Abrasion Index kWh/t TBD TL RDCIS to specify
Average Feed Assay:
-Fe % 62.5 RDCIS To be checked
-SiO2 % 3.5 RDCIS
 -Al2O3 % 2.5 RDCIS

2.4 Primary Crushing Circuit

Operating Schedule h/shift 8 SAIL
shift/day 3 SAIL
h/year 7200 SAIL
Utilization % 83.3 SAIL
Crusher availability % 90 SAIL
Crushing time h/d 18 SAIL
Processing rate, design t/h 2631 DER
Product 80% Passing mm 30 SAIL
Crusher size in. 54 X 74 MEC to be verified
Crusher OSS
-Maximum mm 175 MEC
-Mininmum mm 140 MEC
[Link] Crushing Unit 2 MEC
Maximum Crusher Capacity t/h 1315.4 VEN
Crusher discharge feeder type Apron MEC MEC recomends belt
Dump Pocket Capacity 240 MEC 250
Discharge hopper capacity 438 MEC 500

2.5 Coarse Ore Stockpile

-Live capacity h 24 MEC/SAIL
tonnes 42618
-Total Capacity tonnes 1022831 DER
-Angle of Repose, outside degree 37 RDCIS
-Drawdown Angle degree 55 RDCIS
Reclaim:
-No. of conveyors 1 MEC
-Reclaim feeder type Apron SAIL to specify
-Nos. of feeders 4 MEC

2.6 Beneficiation Circuit- General

Operating Schedule d/y 300 MEC
h/d 24 MEC
Plant Availability % 90 MEC
Processing rate, design t/h 1776 DER
2.6.1 Primary Scrubing Circuit
-Scruber Size ft X ft 32 X 13.25MEC SAIL to specify
-Commercial a'genious W.I kWh/t TBD SAIL to specify
-Scale up factor TBD SAIL to specify
-Design operating power kWh/t 8.2 MEC SAIL to specify
-New feed size(k80) micron 150000 MEC SAIL to specify
-Product Size(k80) micron 800 MEC SAIL to specify
-New feed rate t/h 1776 MEC SAIL to specify
-Selected power kW 7500 MEC SAIL to specify
-Nominal Steel Charge % 6 MEC SAIL to specify
-Design Steel Charge % 10 MEC SAIL to specify
-Mill slurry density %solids 70 MEC SAIL to specify
_______________________

design and execution.

r criterian is identified

MENTS

or the rest of process

Production Requirments - Typical
Example: For 60" X 89" Primary Crusher & Mill feed conveyor system
Operating Schedule calculation - for 3 X 8 hours per shift
Days per year 365
Tonnes per year 32850000
Metric tonnes per day 90000
TOTAL TIME AVAILABLE 8760 Hours per year
PLANNED DOWNTIME
(Subtract planned or known downtimes)
Industrial 0
Electrical - grid 24
Weather 48
Holidays 0
Major Scheduled Maintenance 416 1 X 8 hr maintenance shift/wk
Crusher maintenance 48 1 concave change box 1,2 months
changes 24 X 2
Minor scheduled Maintenance 0
Shift Changes 183 10 minutes/shift
Total lost time 719
PRODUCTION TIME 8041
(Time System is avilable)
System Availability Percentage 91 Production time/total time
UNPLANNED DOWNTIME
(Subtract unplanned downtimes)
No Ore 402 5% of production time(8 hrs/wk no
trucks delivering ore or other reasons)
Crusher plug 161 2% of production time
Chute plug 201 2.5% of production time
Stockpile full 80 1% of production time
Safety Switch 201 2.5% of production time
Metal on belt 52 Approx. 1 hr/wk
Belt repair 241 3% of production time
Electrical 201 2.5% of production time
Mechnical repair 201 2.5% of production time
Others 0
Subtotal Unplanned downtime Hours 1741
RUN TIME(Operating Time) 6300 Prod. Time minus unplanned downtime
Total yearly downtime 2459 Planned and unplanned hours
System Utilization% 78 Run time / prod. Time
Average hours per shift 6.24 Hours per day/3
3 shifts, hours 18.72 Utilization% X 24 hrs
System availability% 72 Runtime hours / total time available
NOMINAL OPERATING RATE 4808 Metric tonne per day / hours in 3 shifts
(Average tonnes per hour)
Conveyor design rate - tph 5769 (1.20 * operating rate)
20% factor added for conv. Selection
 DESIGN OF PLANTS
Major Equipmet Costs in 1972
1972
Equipment Size HP Weight, lb Weight, Kg f.o.b.
price, $
Agitators 3' diam x 3' 1.5 450 204.1 865
5' x 5' 3.0 650 294.8 1,120
10' x 10' 10.0 2,500 1134.0 2,430
16' x 16' 15.0 5,600 2540.1 5,015
28' x 24' 50.0 16,850 7643.0 13,490
40' x 35' 100.0 32,300 14651.0 25,760
50' x 40' 150.0 55,300 25083.7 58,000
60' x 45' 200.0 200 90.7 65,840
0.0
Classifiers Cyclone 3' diam 30 13.6 154
6" 90 40.8 770
10" 150 68.0 1,110
14" 350 158.8 1,320
20" 900 408.2 1,980
26" 1,300 589.7 3,520
50" 3,000 1360.8 10,340
80" 5,300 2404.0 17,600
Rake, simplx 3' x 20' 3.0 6,700 3039.1 7,920
simpex 4' x 25' 5.0 8,525 3866.9 10,090
duplex 5' x 27' 5.0 12,800 5806.0 14,370
duplex 6' x 27' 7.5 14,750 6690.5 15,300
duplex 8' x 27' 10.0 15,150 6871.9 18,680
0.0
Classifiers Spiral 2' x 11' 2.0 3,250 1474.2 3,270
3' x 22' 3.0 8,550 3878.2 6,930
4' x 27' 5.0 16,475 7472.9 11,470
5' x 32' 7.5 26,850 12179.0 18,660
6' x 36.5' 10.0 41,575 18858.1 28,420
7 1/2 x 40' 10.0 50,550 22929.1 34,100
0.0
Conveyors Belt 12" x 50' 2 2525 1145.3 2370
24" x 75' 10 5175 2347.3 13750
24" x 300' 40 17550 7960.5 27500
30" x 50' 10 5300 2404.0 11000
30" x 300' 60 19300 8754.3 39600
36" x 400' 100 34200 15512.9 49400
42" x 480' 200 45800 20774.5 83600
60" x 400' 200 40000 18143.7 79200
72" x 400' 250 47000 21318.8 95700
Drag chain 32' x 18" 5 2000 907.2 5280
52' x 18" 5 3500 1587.6 8170
73' x 18" 5 5000 2268.0 11750
Screw 9" x 13' 1 400 181.4 1230
12" X 13' 1.5 650 294.8 1540
 16" x 13' 3 1170 530.7 2200
0.0
Crushers Gyratory 48" x 80" 350 450000 204116.6 352000
54" x 80" 400 500000 226796.2 419300
60" x 102" 500 750000 340194.3 510000
0.0
Jaw 10" x 36" 50 13290 6028.2 16600
18" x 36" 60 20375 9241.9 22440
25" x 40" 100 37000 16782.9 34903
48" x 66" 250 102000 46266.4 95710
0.0
Standard cone 3' 100 23400 10614.1 29480
4' 200 47100 21364.2 53680
5' 200 91600 41549.1 87230
7' 300 148500 67358.5 154200
0.0
Short head 4 1/4' 150 47400 21500.3 60500
5 1/2' 200 93900 42592.3 99000
7' 300 154600 70125.4 179500
0.0
0.0
Rolls 16" x 10" 10 3750 1701.0 5700
27' x 14" 20 10900 4944.2 12250
36" x 26" 100 17100 7756.4 21600
42" x 26" 125 26875 12190.3 32980
42" x 40" 150 41800 18960.2 50490
55" x 24" 125 65800 29846.4 79200
68" x 24" 150 87600 39734.7 105600
0.0
Apron Feeders 24" x 8' 3 4200 1905.1 4230
36" x 10' 5 6300 2857.6 6534
42" x 15' 10 15000 6803.9 17600
60" x 40' 15 36000 16329.3 31760
84" x 20' 20 40000 18143.7 56900

Vibrating Feeders 30" x 8' 0.0 5500

approximate erection 48" x 8' 3.0 0.0 8580
cost, 7% 60" x 10' 0.0 14300
72" x 10' 6.0 0.0 16300
0.0
Disk Filters 4' diam 3 disc 0.75 3350 1519.5 5700
6' diam 6 disc 1.50 9750 4422.5 14000
9' diam 3 disc 3.50 15450 7008.0 14420
9' diam 6 disc 6.00 21600 9797.6 21090
9' diam 10 disc 8.00 29075 13188.2 28350
Drum Filters 4' diam 4'' long 1.75 4850 2199.9 9040
6' diam 6' long 3.50 10500 4762.7 19200
11 1/2' diam 16' long 7.50 18000 8164.7 33000
14' diam 14' long 10.00 20000 9071.8 41800
0.0
0.0
Vaccum Filters systems 34 cfm 3.5 1050 476.3 1600
200 cfm 11.25 1675 759.8 2770
523 cfm 23 4725 2143.2 7570
2018 cfm 83 14625 6633.8 17300
3135 cfm 137 19100 8663.6 24060
0.0
Flotation cells, per cell; 25 cf 4 1800 816.5 1320
does not include special 40 cf 5 2400 1088.6 1760
junction boxes. 50 cf 7.5 3050 1383.5 1980
100 cf 10 7100 3220.5 4015
300 cf 30 9100 4127.7 6710
500 cf 50 13200 5987.4 9020
0.0
Jigs, approximate 18" x 32" 3 2550 1156.7 2950
erection cost, 10%
24" x 36" 5 3825 1735.0 4260
30" x 36" 5 5225 2370.0 5330
0.0
Mills Ball 3' x 6' 25 12650 5737.9 12177
4' x 6' 40 25050 11362.5 21230
5' x 5' 50 31650 14356.2 25190
6' x 6' 125 62100 28168.1 50060
8' x 8' 300 122800 55701.1 85470
9' x 9' 450 157000 71214.0 114900
11' x 15' 1000 200000 90718.5 148500
13' x 17' 1500 330000 149685.5 242000
17 1/2' x 21' 4000 800000 362873.9 592600
0.0
Mills Rod 4' x 10' 60 35100 15921.1 29900
6' x 12' 200 95500 43318.1 66900
9' x 12' 600 185000 83914.6 133760
10' x 15' 900 200000 90718.5 148000
0.0
Autogenous 28'6" x 5' 2400 0.0 1774500
0.0
Pumps 0.0
Centrifugual 1 1/4" x 1" 1 225 102.1 580
3x3 5 660 299.4 990
5x5 10 1360 616.9 1390
8x6 20 3125 1417.5 2410
10 x 8 40 3875 1757.7 3210
12 x 10 50 5950 2698.9 4520
14 x 12 75 6600 2993.7 5750
16 x 14 100 7025 3186.5 7370
Diapragm 1" Simplex 0.5 350 158.8 1330
2" Simplex 0.75 475 215.5 1460
3" Simplex 1.50 825 374.2 1960
6" Simplex 5.00 4175 1893.7 5462
8" Simplex 10.00 8500 3855.5 8180
10" Simplex 15.00 9675 4388.5 14700
0.0
Samplers 0.0
Automatic 14" 0.25 360 163.3 890
24" 0.25 410 186.0 1020
36" 0.50 610 276.7 1300
48" 0.50 725 328.9 1390
72" 0.50 1050 476.3 1850
96" 0.50 1225 555.7 2118
Vezin 16" 0.33 225 102.1 500
20" 0.33 425 192.8 1500
28" 0.50 600 272.2 1700
40" 0.50 1100 499.0 1800
48" 1.00 1475 669.0 2225
60" 1.00 2450 1111.3 2625
0.0
Screens vibrating 2' x 6' 2.0 1375 623.7 1880
3' x 10' 3.0 1950 884.5 2900
4' x 10' 5.0 3800 1723.7 3630
5' x 12' 7.5 5900 2676.2 5250
6' x 12' 15.0 7000 3175.1 8800
6' x 16' 25.0 9000 4082.3 13200
7' x 16' 30.0 10500 4762.7 17600
8' x 16' 30.0 14500 6577.1 22000
0.0
Thickeners 25' diam 1.5 6000 2721.6 6030
40' 2.0 14450 6554.4 9405
60' 3.0 23000 10432.6 10350
75' 5.0 27000 12247.0 23100
100' 5.0 35650 16170.6 26500
150' 10.0 91450 41481.0 56380
200' 15.0 150000 68038.9 88000
300' 25.0 250000 113398.1 139700
400' 50.0 350000 158757.3 220000

Cost Estimation for a Plant:

The Fixed capital investment for a Plant may be estimated by following steps:

1. Estimated cost of equipment: 10 X a (x)b {Cost of equipment Base 1970 where a,b & x is from following table}
Cost given is corrected for current prices by Machinary and Transport equipment Cost Index of Government of India.

Table: Basic Equipment Cost Data

Item Parameter, x Units of x Range of x a b
diameter of
Cone Crusher feet 2-7 4154 1.8
discharge annulus
 receiver opening 30X55 -
Primary gyratory crusher times mantle [Link] 3.58 1.41
60X109
diameter
Jaw Crusher area of feed opening [Link] 15X24-60X48 6 1.28
Hammer Mill area of feed opening [Link] 6X4-46X60 217 0.67
Ball Mill motor HP HP 40-1750 3410 0.54
Rod Mill motor HP HP 50-1500 2955 0.57
Cyclones diameter inches 6-30 132 0.91
SRL pumps Capacity USGPM 250-5000 31 0.64
Dust Collector Capacity [Link]. /min. 2000-10000 10.6 0.72
DDVibrating Screen(Sec) Screen area sq. ft. 6X16-8X20 370 0.76
Spiral Classifier Spiral Diameter inches 24-78 30 1.53
Table Deck Area sq. ft. 24-90 618 0.35
Floatation Cell Volume [Link]. 100-300 71 0.74
Jig Capacity ton/day 45-400 1120 0.17
Steel Mixing Tank Volume US Gal. 100-250000 44 0.53
Disc Filter Filter area sq. ft. 22-1800 1194 0.44
Drum Filter Filter area sq. ft. 12-720 4331 0.33
Thickener Diameter ft. 10-225 147 1.38
Vib. Feeder Feeder area [Link] 2880-13824 1.28 0.99
36" belt conveyor Length betn centers ft. 200-1000 34 1.13
Motor 1800 rpm Horsepower HP 250-600 15.3 1.11

[Link] Plant Cost:

The procedure for estimating total plant cost is shown in Table below:

Factored Capital Cost Estimate Guide

1. Purchased equipment costs from references and on current index basis

2. Installed equipment costs
a. From References and on current index basis or
b. Item 1 multiplied by 1.43

3. Process Piping
Type Plant: Percent of Item 2
Solid 7 - 10
Solid-Fluid 10 - 30
Fluid 30 - 60

4. Instrumentation
Amount of automatic control: Percent of Item 2
None 3-5
Some 5 - 12
Extensive 12 - 20

5. Building and site development

Type Plant: Percent of Item 2
Outdoor 10 - 30
Outdoor - Indoor 20 - 60
Indoor 60 - 100
6. Auxiliaries (e.g., electric power)
Extent: Percent of Item 2
Existing 0
Minor additions 0-5
Major additions 5 - 25
New facilities 25-100

7. Outside lines
Average length: Percent of Item 2
Short 10 - 30
Intermediate 20 - 60
Long 60 - 100

8. Total Physical plant costs = Sum of Items 2+3+4+5+6+7

9. Engineering and construction

Complexity: Percent of Item 8
Simple 20 - 35
Difficult 35 - 60

10. Contingencies
Type Process: Percent of Item 8
Firm 10 - 20
Subject to Change 20 - 30
Speculative 30 - 50
Average 30

11. Size Factor

Size Plant: Percent of Item 8
Large Commercial 0-5
Small Commercial 5 - 15
Pilot Plant 15 - 35

12. Total Plant of fixed Capital Costs = Sum of 8+9+10+11

Marshal and Swift Index(Mining & Milling):

Year Index Value

1950 167.9
1951 180.3
1952 180.5
1953 182.5
1954 184.6
1955 190.6
1956 208.8
1957 225.1
1958 229.2
1959 234.5
 1960 237.7
1961 237.2
1962 238.5
1963 239.2
1964 241.8
1965 244.9
1966 252.5
1967 262.9
1968 273.1
1969 285.0
1970 303.3
1971 231.3
1972 332.0
1973 344.1
1974 398.4
1975 444.3
1976 472.1
1977 505.4
1978 545.3
1979 549.4
1980 659.6
1981 721.3
1982 745.6
1983 760.8
1984 780.4
1985 789.6
1986 797.6
1987 813.6
1988 852.0
1989 895.1

2006
2007 1326.4
2008 1st 1427.2
2008 2nd 1443.4
PLANTS
2006 f.o.b.
Remarks % Esc Crore rupees
price, Rs

Uncludes speed 0.0 175486.1 0.02

reducer, 0.1 227218.9 0.02
shaft, turbine 0.1 492983.9 0.05
impeller, drive, and 0.3 1017413.4 0.10
otor. No tank or 0.8 2736770.9 0.27
superstructure.
1.5 5226035.5 0.52
Approximate erection
cost, 5%. 3.3 11766694.8 1.18
3.7 13357227.4 1.34

Rubber line. 0.0 31242.6 0.00

Approximate 0.0 156213.0 0.02
erection cost, 5%. 0.1 225190.2 0.02
0.1 267793.7 0.03
0.1 401690.6 0.04
0.2 714116.7 0.07
0.6 2097717.7 0.21
1.0 3570583.3 0.36
With motor and drive. 0.4 1606762.5 0.16
Approximate erection 0.6 2046999.2 0.20
0.8 2915300.1 0.29
0.9 3103973.0 0.31
1.1 3789687.2 0.38

Includes motor and 0.2 663398.1 0.07

drive. 0.4 1405917.2 0.14
Single spiral. 0.6 2326965.3 0.23
Approximate erection 1.1 3785629.8 0.38
cost, 5%. 1.6 5765680.5 0.58
1.9 6918005.1 0.69

Inclined conveyors 0.1 480811.5 0.05

with 0.8 2789518.2 0.28
idlers, belt, scrapers, 1.5 5579036.3 0.56
takeup, reducer 0.6 2231614.5 0.22
drive, motor, and 2.2 8033812.3 0.80
walkway.
2.8 10021978.0 1.00
Approximate erection
cost, 20%. 4.7 16960270.5 1.70
4.5 16067624.7 1.61
5.4 19415046.5 1.94
With motor and drive. 0.3 1071175.0 0.11
Approximate erection 0.5 1657481.0 0.17
cost, 15% without 0.7 2383770.1 0.24
motor or drive. 0.1 249535.1 0.02
Approximate erection 0.1 312426.0 0.03
cost 15%.
With motor and drive.
Approximate erection
cost, 15% without
motor or drive.
Approximate erection
cost 15%.
0.1 446322.9 0.04

With motor, drive, 19.8 71411665.3 7.14

and lube 23.6 85065088.8 8.51
system. Approximate 28.7 103465765.0 10.35
erection cost, 8%
With motor and drive. 0.9 3367709.2 0.34
Approximate erection 1.3 4552493.7 0.46
cost, 8%. 2.0 7080912.9 0.71
5.4 19417075.2 1.94

With hydraulic 1.7 5980727.0 0.60

setting, 3.0 10890279.0 1.09
motor, drive, and 4.9 17696703.3 1.77
lube system. 8.7 31283178.4 3.13
Approximate erection
With hydraulic 3.4 12273880.0 1.23
setting, 5.6 20084530.9 2.01
motor, drive, and 10.1 36415891.8 3.64
lube system.
Approximate erection
Includes motor and 0.3 1156382.1 0.12
drive. 0.7 2485207.1 0.25
Approximate erection 1.2 4382079.5 0.44
cost, 8%. 1.9 6690786.1 0.67
2.8 10243110.7 1.02
4.5 16067624.7 1.61
6.0 21423499.6 2.14

Includes motor and 0.2 858157.2 0.09

lube 0.4 1325579.0 0.13
sysetm. Approximate 1.0 3570583.3 0.36
erection cost, 7%. 1.8 6443279.8 0.64
3.2 11543533.4 1.15

Electromagnetic, 0.3 1115807.3 0.11

Mechanical. 0.5 1740659.3 0.17
Electromagnetic 0.8 2901098.9 0.29
Mechanical. 0.9 3306847.0 0.33

Includes motor and 0.3 1156382.1 0.12

drive but 0.8 2840236.7 0.28
not vaccum 0.8 2925443.8 0.29
equipment. 1.2 4278613.7 0.43
Approximate erection 1.6 5751479.3 0.58
Includes motor and 0.5 1833981.4 0.18
drive but 1.1 3895181.7 0.39
not vaccum 1.9 6694843.6 0.67
equipment. 2.4 8480135.2 0.85
Approximate erection
Includes dry vaccum 0.1 324598.5 0.03
pump, 0.2 561961.1 0.06
blower, filtrate pump. 0.4 1535756.6 0.15
Approximate erection 1.0 3509721.0 0.35
cost, 8%. 1.4 4881149.6 0.49

Includes motor and 0.1 267793.7 0.03

drive. Approximate 0.1 357058.3 0.04
erection cost, 22%. 0.1 401690.6 0.04
0.2 814539.3 0.08
0.4 1361284.9 0.14
0.5 1829923.9 0.18

2-Compartment Harz
type with 0.2 598478.4 0.06
motor and drive. 0.2 864243.4 0.09
0.3 1081318.7 0.11

With liners, feeders, 0.7 2470397.3 0.25

motors, 1.2 4307016.1 0.43
drives, lube system. 1.4 5110397.3 0.51
Approximate erection 2.8 10155874.9 1.02
cost, 6%. 4.8 17339645.0 1.73
6.5 23310228.2 2.33
8.4 30126796.3 3.01
13.6 49095519.9 4.91
33.4 120223161.5 12.02

Includes liners, motor 1.7 6065934.1 0.61

and drives,lube 3.8 13572273.9 1.36
system. 7.5 27136432.8 2.71
Approximately 8.3 30025359.3 3.00
erection cost, 6%.
100.0 360000000.0 360000000.00

includes motor and 0.0 117666.9 0.01

drive for 40-ft head. 0.1 200845.3 0.02
Approximate erection 0.1 281994.9 0.03
cost, 30%. 0.1 488926.5 0.05
0.2 651225.7 0.07
0.3 916990.7 0.09
0.3 1166525.8 0.12
0.4 1495181.7 0.15
Adjustable stroke 0.1 269822.5 0.03
includes motor and 0.1 296196.1 0.03
drive. Approximate 0.1 397633.1 0.04
erection cost, 30%. 0.3 1108098.1 0.11
0.5 1659509.7 0.17
0.8 2982248.5 0.30
 Size refers to cutter 0.1 180557.9 0.02
travel. 0.1 206931.5 0.02
Includes track, cover, 0.1 263736.3 0.03
and motor. 0.1 281994.9 0.03
0.1 375317.0 0.04
0.1 429687.2 0.04
5% final split, add 0.0 101437.0 0.01
$25 for 10% 0.1 304311.1 0.03
final sample split. 0.1 344885.9 0.03
Approximate erection 0.1 365173.3 0.04
cost, 30%. 0.1 451394.8 0.05
0.1 532544.4 0.05

Double-deck 0.1 381403.2 0.04

includes motor 0.2 588334.7 0.06
and drive but not 0.2 736432.8 0.07
screen cloth. 0.3 1065088.8 0.11
Approximate erection 0.5 1785291.6 0.18
cost, 5%.
0.7 2677937.4 0.27
1.0 3570583.3 0.36
1.2 4463229.1 0.45

Includes mechanism 0.3 1223330.5 0.12

with rake, 0.5 1908030.4 0.19
rake lift, 0.6 2099746.4 0.21
superstructure rakes, 1.3 4686390.5 0.47
feed-well, drive, and 1.5 5376162.3 0.54
motor but not tank.
3.2 11438038.9 1.14
Approximate erection
cost, 9%. 5.0 17852916.3 1.79
7.9 28341504.6 2.83
12.4 44632290.8 4.46

a,b & x is from following table}

Index of Government of India.

503703 20148117.175
 4E+06 171488477.31
66807 2672277.9681
634108 20291445.556

4788

51537 2319146.7006
112052 4145931.0195

29534 1329049.4797

1E+06 37865078.746
47125 1743616.9617
236819 8762299.3183

100.0

143.0

10.0

14.3

57.2
 7.2

14.3

246.0

61.5

73.8

12.3

393.5
Froth Flotation Processes and equipments are
1 Mechnical
-Self aerating cells: Wemco and Denver
-Forced draft; Outokumpu, Dorr Oliver, Agitair.
2 Pneumatic
-Column with height to diameter ratio of 10:1
-Jameson cell with height to Diameter ratio of 2:1.

Raw Data Requirements

1 Performance of bench scale mechanical flotation tests to define recovery time curve for valuable mineral.
Concentrate samples are initially collected over small time increments.(Pneumatic or Mechnical)
2 If Pneumatic then small pilot plant column or Jameson cell is run to confirm that these less expancive processes are

Test Result: Lab Pilot

Time,min Recovery%Recovery%
0 0 0
Recovery Chart
1 20 1 100
1.5 40 2 90
2 60 3 80
2.5 78 5 70
60

Recovery%
3 85 7
5 93 20 50
7 96 60 40
30
10 96 88
20
15 93 10
20 95 0
25 98 0 5 10 15 20
Floatation Time, min

From Recovery Chart: To achive 88% recovery, the scale up factor for roughers is =10/4 2.5

Rougher retaintion time = 10 min(88% recovery)

Scavenger retaintion time = 9 min(95% recovery)
Solid feed rate = 500 t/h
pulp flow at flotation density = 1100 m3/h
rougher/scavenger flotation volume = 348 m3

If one bank cells at 38 m3 nominal size is assumed:

Then net volume = 36 m3
Since the design is based on pilot plant work air entrainment has been taken into account.
So no. of cells in the bank = 10 cells
or valuable mineral.

less expancive processes are viable.

very Chart

10 15 20 25
oatation Time, min
Leaching
Carbon in Leach(CIL) or Carbon in pulp(CIP) Circuit.
Enabling any such circuit to know the order of magnitude with minimum test work.

Data required for preliminary Design

Nominal UPFO Ex.
T - Plant throughput, t/h - 1 t/h 100
Cw - solids concentration in CIL/CIP circuit, %w/w 40 - 50 4.13 % 40
S - solids specific gravity 2.6 - 2.8 4.2 2.65
t - residence time, hrs 24 mininmum 3 hrs 24
N - total no. of tanks 6-8 3 6
n1 - no. of leach tanks 1-2 3 1
n2 - no. of CIL/CIP tanks 5-6 3 5
A - aspect ratio
(=tank diameter/working heights) 1 - 1.2 1 1

The following values are therefore formulated:

Q - plant throughput, m3/h

D - nominal diameter of tank, m
H1 - slurry level within tank, m
H - total height of tank, m
V - total live volume of tankage train, m3
V1 - live volume of individual tanks, m3

Q = (100/Cw - 1 + 1/S) T m3/h 23.45 m3/h 187.74

V = Qt m3 70.35 m3 4505.66

The volume of each individual tank is given by:

V1 = V / N m3 23.45 750.94

Using this information it is possible to size each individual tank by:

V1 = ∏D2H1 / 4

Assuming aspect ratio 1, then D will be calculated:

D = H1 = (4V1 / ∏)0.33 m 3.07 9.63

Allow an additional 500 mm for tankage freeboard, hence

H = H1 + 0.5 m 3.57 10.13

 L

The overall dimensions of the CIL/CIP area pad, based upon a nominal clearance of 750 mm between tanks is given by:

L = 3.5 D + 3.38 m 14.12 m 37.08

W = 1.87 D + 2.15 m 7.89 m 20.16

t/h
%

hrs

m3/h

m3

m3

m
 W

ween tanks is given by:

m
 Krebs Cyclone Performance Chart
4 PSI 15 PSI 30 PSI
Model Cut range Min. Capcity Max. Capacity Min. Capcity Max. Capacity Min. Capcity Max. Capacity
µ US-GPM US-GPM US-GPM US-GPM US-GPM US-GPM
D-4 25 - 65 11 27 20 50 28 70
D-6 35 - 75 36 80 70 150 99 210
D-10 40 - 100 50 175 90 300 140 450
D-15 50 - 110 175
D-20 60 - 120 580 1100 1600
D-26 70 - 150 800 1400 1600 2500 2100 3500
D-30 100 - 200 1400 2300 2600 4500 3700 6200
D-50 150 - 250 3700 4900 7000 9000 10000 12000

1 GPM = 0.227125 m3/hr 1 PSI = 6.894757 Kilopascal 0.06894757 bar

4 PSI 15 PSI 30 PSI

Model Cut range Min. Capcity Max. Capacity Min. Capcity Max. Capacity Min. Capcity Max. Capacity
µ m3/hr m3/hr m3/hr m3/hr m3/hr m3/hr
D-4 25 - 65 2.50 6.13 4.54 11.36 6.36 15.90
D-6 35 - 75 8.18 18.17 15.90 34.07 22.49 47.70
D-10 40 - 100 11.36 39.75 20.44 68.14 31.80 102.21
D-15 50 - 110 39.75 0.00 0.00 0.00 0.00 0.00
D-20 60 - 120 0.00 131.73 0.00 249.84 0.00 363.40
D-26 70 - 150 181.70 317.97 363.40 567.81 476.96 794.94
D-30 100 - 200 317.97 522.39 590.52 1022.06 840.36 1408.17
D-50 150 - 250 840.36 1112.91 1589.87 2044.12 2271.25 2725.50

Feed Characteristics:
1. The feed solids must have an average specific gravity in the range 2.5 to 3.2. Liquid must be water or an aqueous solution.
2. The feed concentration must be no greater than 30 percent solids by weight.
3. The feed must not be unusually viscous as might be true for feed with a high content of clay or primary slimes.

See the apex dia chart for underflow dry solid t/hr vs apex dia and accordingly choose the apex.

Cyclone Selection:
Table 1. Relationship of D50c to Overflow Size Distribution

Req. O/F Size Distribution Multiplier

(% Passing) of Specified micron size (to be multiplied times micron size)

98.8 0.54
95 0.73
90 0.91
80 1.25
70 1.67
60 2.08
50 2.78
Primary Grinding Circuit:
Problem: Select the proper size and number of cyclones for a rod mill/ball mill circuit where new feed to the rod mill is 250 mtph solids.
Both mill discharges join together at cyclone feed sump and are pumped to cyclones.
Overflow is to be 60%-200#(74 micron) at a minimum of 40% solids by weight.
Underflow becomes ball mill feed.
SG of solids is 2.9 and estimated circulating load is 225%.

SG Solid 2.9 3.73

SG Liquid 1 1

Step 1: Calculate material balance from known information. Overflow must be 250 mtph at 40%.
O/F
mtph solids: 250
mtph Water: 375
mtph Slurry: 625
%solids, wt: 40
Sp. Gravity Slurry: 1.355
l/sec slurry: 128.1
USGPM of Slurry: 2030.6

U/F (based on 2.25 x overflow) CL 2.25

mtph solids: 562.5
mtph Water: 187.5
mtph Slurry: 750
%solids, wt: 75
Sp. Gravity Slurry: 1.966
l/sec slurry: 106.0
USGPM of Slurry: 1679.5

Feed (Sum of overflow and underflow)

mtph solids: 812.5 260

mtph Water: 562.5 2038
mtph Slurry: 1375 2298
%solids, wt: 59.1 11.3
Sp. Gravity Slurry: 1.632 1.080
l/sec slurry: 234.1 591.0
USGPM of Slurry: 3710.2 9367.8
%solids, vol. 33.2 4.2
(Necessary for separation calculations)
Step 2: Calculate required D50c for specified overflow of 60% passing 74 microns.
From Table 1:
Multipler at 60 passing = 2.08 0.54
Specified micron size = 74 μ 70
D50c(application) = 153.92 37.8

Step 3: Calculate cyclone diameter required.

First calculate C1, C2 and C3:

C1 = Correction for feed density = 4.10 1.13

C2 = Correction for ΔP(pressure drop) = 1.09 (Pressure drop assumed at 50 kPa(7 psi) which 1.09
would be low energy and good maintenance.)
C3 = Correction for sp. Gravity solids = 0.93 1.00

Second, calculate cyclone diameter:

D50c(application) = D50c(base) X C1 X C2 X C3

D50c(base) = 37 μ 30.75

Cyclone diameter = D= 49 cm 37
D= 20 inch 15

Step 4: Calculate number of units required.

From Fig.9:
Flow rate for 20 inch cyclone at 7 psi = 40 lt./sec 28 443.809
Total feed flow = 234.1 lt./sec 591.0 9367.8
Therefore, no. of units required = 6 22

Step 5: Calculate proper apex size.

Total underflow = 106.0 lt./sec
Underflow per unit = 18 lt./sec
Flow rate in USGPM = 285.3 gpm
From Fig.10 each apex will be of size = 3.75 inch
9.525 cm

Step 6: Calculate inlet and VF Diameter.

Area of inlet nozzle = 20 [Link].
Circular dia. Of inlet nozzel = 5 inch
Square length of inlet nozzle = 4 inch
VF Diameter = 7 inch
[Link] for Motor and Mill Size
1. Bond Method for calculating power of Mill:
Blue Dust Jig Conc.
F - Feed Size (d80)- in µ = 1000 µ 4282 µ
P - Product Size (d80)- in µ = 45 µ 45 µ
Wi - Work Index = 14 11.2
W=Power Consumption in kwh/t = 11 X Wi X (1/√P - 1/√F)
W = 18.09 kwh/t 16.48 kwh/t

Quantity of Mass to be grounded 684 t 718.5 t

PM = Mill Power in kw = 12371.55 kw 11842.92 kw
PM = Mill Power in HP = 16577.87 HP 15869.52 HP

Correction factor on Power

[Link] Grinding, closed Circuit =W 12371.55 kw 11842.92 kw
[Link] Grinding, open Circuit, Product top size not limited =W
[Link] Grinding, open Circuit, Product top size limited =W to 1.25W
[Link] Grinding, closed Circuit =1.30 W
[Link] Grinding, open Circuit, Product top size not limited =1.30 W
[Link] Grinding, open Circuit, Product top size limited =1.30 W to 2.0 W

7. If P is less than 80% passing 70µ. Power consumption will be W((P+10.3)/(1.145P)) 13277.95 kw 12710.6 kw

Step-I Calculated corrected Power = 13277.95 kw 12710.60 kw

Step-II Convert kW in HP = 17792.46 HP 17032.2 HP
Step-III If Power is very large value then divide
it in 2,3,4……n. nos. of mill 3 3 Mill Dia. Factor-A %C.S - Length
Step-IV Mill Power for each Mill 5930.82 HP 5677.40 HP 65 71
Step-V Use HP = A X B X C X L 12 88.4 89.7 79.1
A= Factor for diameter inside shell lining 12.6 97.5 81.3 71.7
B= Factor which include effect of % loading & mill type 13 108.0 73.4 64.7
C= Factor for speed of mill 14 130.0 61.0 53.8
L= Length in ft of grinding chamber measured 15 154.5 51.3 45.2
beetween head liner at shell to head 16 181.5 43.7 38.5
junction
Step-IV Calculate length at diff %.CS & %laoding %loading Factor-B
Step-VI Choose best L/D Ratio for application. 40 5.02
 ROD - 1.2/1 to 1.6/1
Ball - 1/1 to 5/1
Speed less then less wear of liner &Ball
Speed more then less capital cost

[Link] for Critical Speed

Critical Speed(in rpm) = 76.63/√D Where D = internal diameter of mill in feet, measured inside shell liners

Ex. Let 11ft dia. Mill operate at 17.3 rpm then C.S. = 76.63/√11 = 23.1 rpm
Mill speed expressed as percent of critical speed is 17.3/23.1 = 75% Critical Speed

[Link] of Charge Volume

Charge volume as %loading = 113 - 126( H

/ D)
 Diameter Speed Mill Type and Loading
Dia. Inside Sheell Liners(ft) in meter Factor A % C.S Factor C
8.00 2.44 32.0 60 0.1340 % Loading Ball Mill
8.50 2.59 37.3 61 0.1370 Dry Wet
9.00 2.74 43.1 62 0.1400 Diaph. Diaph.
9.50 2.90 49.6 63 0.1430 20 4.30 3.87
10.00 3.05 56.1 64 0.1460 22 4.57 4.12
10.50 3.20 63.5 65 0.1490 24 4.80 4.32
11.00 3.35 71.1 66 0.1521 26 5.07 4.57
11.50 3.51 79.3 67 0.1552 28 5.31 4.77
12.00 3.66 88.4 68 0.1583 30 5.53 4.97
12.50 3.81 97.5 69 0.1625 32 5.71 5.14
13.00 3.96 108.0 70 0.1657 34 5.90 5.32
13.50 4.11 118.5 71 0.1690 36 6.05 5.45
14.00 4.27 130.0 72 0.1724 38 6.16 5.55
14.50 4.42 141.5 73 0.1760 40 6.27 5.65
15.00 4.57 154.5 74 0.1798 42 6.34 5.70
15.50 4.72 167.2 75 0.1838 44 6.41 5.77
16.00 4.88 181.5 76 0.1878 46 6.46 5.82
16.50 5.03 196.0 77 0.1918 48 6.49 5.84
17.00 5.18 211.2 78 0.1958 50 6.50 5.85
17.50 5.33 226.7 79 0.1999
18.00 5.49 243.6 80 0.2040
18.50 5.64 260.5 81 0.2081
19.00 5.79 278.9 82 0.2124
19.50 5.94 297.8 83 0.2166
20.00 6.10 317.1 84 0.2208
85 0.2251
86 0.2294
87 0.2337
 BALL MILL POWER CALCULATION(sail)
1 FEED RATE 1000 tph
2 FEED SIZE 3800 microns
3 PRODUCT SIZE 670 microns
4 WORK INDEX 14 KW/St
15.428 KW/T
5 Peridicted mil energy consumption
W= (100)^0.50XWi/(P)^0.50 - (100)^0.50XWi/(P)^0.50
W predicted mill energy consumption in kWh/st
Wi Work index,in kWh/st
100 100 microns, which is the product size in the definition of work index.
P,F 80% passing sizes, in micron of the feed (F) and Product(P)

W 3.14 kWh/st

Efficiency factor
1 EF1(Dry grinding) NA
2 EF2(Opencircuit grinding) NA
3 EF3(Diameter efficiency factor) NA
As mill dia inside liners exceed 2.44 m(8 ft),there is a tendency to neglect the EF3 factor .
4 EF4(oversized feed) NA
Applies when feed is coarser than the optimum size of feed(Fo)
Fo= 4000*(13/Wi)^0.5
Fo= 3854.496
As 3800 microns is finer than Fo,hence factor not applied
5 EF5(Fineness of Grind ) NA
Applied when the 80% passing size of the product is finer than 75 microns
6 EF6(high or low ratio of reduction rod NA
milling)

7 EF7(low ratio of reduction ball mill)

Applies when the ratio of reduction is less than 6
EF7= (2(Rr - 1.35)+0.26)/(2(Rr-1.35))
Rr 5.672
EF7 1.030
 8 EF8(Rod Milling ) NA

(W*EF1*EF2*EF3*EF4*EF5*EF6*EF7*EF8)*1.102*1.341*feedrate HP
4776.12 HP
3561.61 Kw
Let us consider No Millls 3
Therefore the power/Mill 1592.041 HP

From table Ball mill :

Ball mill diameter 3.81 m
length 3.66 m
ball size 50 mm
power at 40 % loading 954 HP
ball charge weight at 40% loading 112 T

Totalpower ( As per mill chart) 954 HP

Mill power and /or volume can be changed by changing the mill [Link] the same mill diameter, mill volume and power are directly propotional to change in the effect
length of the grinding chamber. 1.6688

Length 6.11 meters

1.603105
C.S - Length %C.S - Length/Dia. Ratio
85 65 71 85
59.4 7.5 6.6 4.9
53.8 6.5 5.7 4.3
48.6 5.6 5.0 3.7
40.4 4.4 3.8 2.9
34.0 3.4 3.0 2.3
28.9 2.7 2.4 1.8
 Mill Type and Loading
Factor B
Ball Mill Rod Mill
Wet Dry Wet Wet
Overflow Peripheral Peripheral Overflow
3.44 4.73 4.25 3.78
3.66 5.04 4.54 4.03
3.84 5.27 4.75 4.22
4.06 5.58 5.02 4.47
4.24 5.82 5.24 4.66
4.42 6.08 5.47 4.86
4.57 6.28 5.65 5.02
4.72 6.48 5.83 5.19
4.84 6.67 6.00 5.33
4.93 6.78 6.10 5.42
5.02 6.90 6.21 5.52
5.08 - - -
5.13 - - -
5.17 - - -
5.19 - - -
5.20 - - -
potional to change in the effective grinding
Mill Operating Cost Spreadsheet:
Budget - Concentrator Consoli
in '000s Rs April May June July August Sep Oct
Manning
-Salaries
-Operator Wages
Total
Materials / Supplies
-Grinding Media
-Mill Liners
-Filter Cloths
-Power
-Other
Total
Reagents
-Collector
-Modifier
-Frother
-Flocculant
Total
Maintenance
-Labour
-Supplies
Total
Contractors
-Transport
-General
Consultants
-Metallurgy
-Head Office
Total
Administration
-Travel
-Training
-General
-Recoveries
Total
Total Expenses

Process Design Criteria

Process site conditions:
- Location
-Ambient temperatures
 -Evaporation
-Rainfall
-Relative humidity
-Likelihood of flooding,cyclone, earthquake, or extreme natural events.

Operating Schedule:
-Crushing plant h/d
d/w
w/y
-Crushing plant availability% (80)
-Treatment plant h/d
d/w
w/y
-treatment plant availability% (90)
-Throughput t/y
-Crushing plant t/d
-Treatment plant t/d

Ore Characteristics:
-Feed grades
-sg
-Crushed bulk density
-Moisture %

Crushing plant(if applicable):

-ROM feed size mm
-Feed to secondary and tertiary crushers mm
-Crushed product size mm
-Throughput t/h

Grinding plant:
-Feed rate t/h
-Feed size mm
-Work index kWh/t
-Mill product size mm

Treatment plant:
-Feed and pulp flowrates m3/h
-Reagent consumption Kg/t

Final product:
-Drying and packing requirements

Water circuit:
-Consumption m3/h
-Water recovery %
ntrator Consolidated
Nov Dec Jan Feb March
1Volumetric calculation in bunkers:
A. Rectangular: Bunkers
L

L1
B1 B

B. Circular: Silo

D
Let
D= 5
d= 1
H= 3

Therefore, Volume may be calculated as = PI/12 X H X (D2 +

H So, Volume V =
Effective Volume =
24.35 m3
17.04 m3

Let Bulk Density = 2.50 t/m3

Quantity in term of M 42.61 t

C. Silo:
D
Calculation-I
d= 1.5 m h=

Variable D= d+2Xh/tan(700) = 8.00

Fix d= 1.5
 h= 8.93
H= 10

H
So, Lower Volume V1
Effective Volume =

Let Bulk Density =

Quantity in term of M

Circular Volume V2 =
Effective Volume =

Let Bulk Density =

Quantity in term of M

h Total Quantity in Silo

d
 Let
L= 5m A1 = LXB 12.5 m2
L1 = 1m A2 = L1 X B1 0.5 m2
B= 2.5 m
B1 = 0.5 m
H= 3m

H Therefore, Volume may be calculated as = H/3 X (A1+A2+√(A1 X A2))

So, Volume V = 15.50 m3

Effective Volume = 10.85 m3

Let Bulk Density = 2.50 t/m3

Quantity in term of M 27.13 t

ulated as = PI/12 X H X (D2 + d2 + (D X d))

Calculation-II
8.93 m Fix D= 8
d= 1.5
H= 10
m Variable h = 8.93
m
m
So, Lower Volume V1 182.92 m3 A1=
Effective Volume = 128.05 m3 A2=
182.96 m3
128.07 m3 Let Bulk Density = 2.50 t/m3
Quantity in term of M 320.12 t
2.50 t/m3
320.18 t Circular Volume V2 = 502.6548
Effective Volume = 351.86 m3
502.7187
351.90 m3 Let Bulk Density = 2.50 t/m3
Quantity in term of M 879.65 t
2.50 t/m3
879.76 t Total Quantity in Silo 1199.76 t

1199.94 t
50.26548
1.767146
Design of Belt Conveyors:
Requirements:
Capacity to be handled = 800 t/h
Bulk Density = 1.6 t/m3

Design Calculations:
1 Volume 500 m3
2 Velocity 1.53 m/s (Select belt speed more than this value)

3 Calculate the gradient of start to end point

Let us take 1 degree (Max. 140 and 100 safe)
4 See the total horizontal distance to be travel, let 1500 m
5 Divide in diffent section of individual h. distance, let 4
6 Each section length = 375 m
7 For taken inclination, vertical lift to be calculated = 6.55 m
8 Calculate the vertical distance of two belt transfer = 4 ( Between 3.5 to 4.0)
9 Calculate total vertical lift = 38.18 m

10 Select the belt speed 2 m/s

11 Capacity 800 t/h
12 Design Capacity 960 t/h
13 Caculate weight per meter run =mG = 133.33 kg/sec
14 Frictional coefficient = f = 0.03 ( Between .012 or .02 to .03)
15 Mass of Carrying roller = mc = 50 kg/m
16 Mass of return roller = mr = 20 kg/m
17 Mass of belt = mb = 20 kg/m

18 Calculate effective tension using formula as given

Te = f x L x g [mc+mr+([Link]+mG)cosδ ]+mG x H x g + Rsecondary 35416.58 N

19 Calculate Power required P =( Te X v )/1000 = 70.83 kW

20 Add power for Rsecondary as thumb 4 kW
21 Total Power requred for belt = P = 74.83 kW
22 Motor Power, consider efficiency η = P/η = 93.54 kW
 T1

Te = T1 - T2
20
T2

(Max. 140 and 100 safe) 500

Area of carrying solids = 0.090993 m2

n .012 or .02 to .03)