Metallurgical Balances

Overview of 2-Product and 3-Product Formulas

Metallurgical Balances
Uses
steady-state accounting of mass flows in a system evaluation of metallurgical testwork comparison of two different mills or circuits process control of an operation plant

Properties of the Balance

requires samples for assay and weights/flowrates accuracy of the assays used turnaround time of the assays

Metallurgical Balances
The method relies on equations and tables Equations
2-Product Formula C F=C+T Ff = Cc + Tt where F = feed tonnage rate or 100% C = concentrate tonnage or weight% T = tailing tonnage or weight% and f, c, t = assay of each respective stream (%, g/t, ppm, etc.) F T

Two-Product Formula
There are 6 variables Total Mass

Species Analysis

Step 1: Step 2: Step 3:

F and f C and c T and t Reduce number of variables to 5 by setting F = 100 Obtain the value of three variables Calculate the remaining two variables

Two-Product Formula
The calculation can be done using the formula or by simply filling in a Table. If f, c, and t are the three measured variables, then the formula is used.

If other variables are given, then the Table is simply filled in

Metallurgical Balances
2-Product Formula Solution
C = 100 * (f-t)/(c-t)

%Recovery = 100 * c(f-t) /f(c-t)

f

The Metallurgical Balance Table

Product Weight% Assay (%)

Units

%Recovery

Concentrate
Tailing Feed

C T
100

c t f

Cc Tt 100f

Cc/f Tt/f
100

Two-Product Formula
Given the following three variables: All Assays Calculate the Weight% of C: C = F * (f t) / (c t)
C = 100(1.29-0.072) / (26.9-0.072) Product Weight Weight% %Cu Cu Units %Recovery (tpd) Concentrate 1,135 4.54 26.9 122.126 94.67 Tailing 23,865 95.46 0.072 6.873 5.33 -----------------------------------------------------------------------------------------------------------------Feed 25,000 100.00 1.29 128.999 100.00

Two-Product Formula
Given the following four variables: Product Weights Product Assays
Product Weight Weight% %Cu Cu Units %Recovery (g) Concentrate 45.3 4.542 26.9 122.180 94.67 Tailing 952.1 95.458 0.072 6.873 5.33 -----------------------------------------------------------------------------------------------------------------Feed 997.4 100.00 (1.291) 129.053 100.00

Two-Product Formula
Given the following three variables: %Recovery %Cu in Concentrate %Cu in Feed
Product Weight Weight% %Cu Cu Units %Recovery (tpd) Concentrate 1,135 4.540 26.9 122.124 94.67 Tailing 23,865 95.460 0.072 6.876 5.33 -----------------------------------------------------------------------------------------------------------------Feed 25,000 100.00 1.29 129.00 100.00

Metallurgical Balances
The method relies on equations and tables Equations
3-Product Formula F = C1 + C2 + T Ff1 = C1c11 + C2c21 + Tt1 Ff2 = C1c12 + C2c22 + Tt2 where C1 C2 F

F = feed tonnage rate or 100% C1 and C2 = concentrate1 and 2 tonnage or weight% T = tailing tonnage or weight% and f1, c11 , c21 , t1 = stream assay for element 1 (%, g/t, ppm, etc.) f2, c12 , c22 , t2 = stream assay for element 2 (%, g/t, ppm, etc.)

Metallurgical Balances
Lets examine application of the 2-product formula Equations
2-Product Formula to solve in stages
f1 = 1.29 %Cu f2 = 4.32 %Zn

t1 = 0.072 %Cu t2 = 0.342 %Zn

c11 = 26.9 %Cu c12 = 9.25 %Zn

C1

C2

c21 = 1.10 %Cu c22 = 57.7 %Zn

We need the assays of the intermediate product T1 (t11 and t12) Step 1 Step 2 Ff1 = C1c11 + T1t11 then T1t12 = C2c22 + Tt2 100 = C1 + T1 and T1 = C2 + T
Check that the assays of element 2 in Circuit 1 are balanced Check that the assays of element 1 in Circuit 2 are balanced

Metallurgical Balances
Lets examine application of the 2-product formula Equations
First step: Ff1 = C1c11 + T1t11 100 = C1 + T1 So C1 = 100(1.29 - 0.104) / (26.9 - 0.104)
c11 = 26.9 %Cu c12 = 9.25 %Zn f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
t11 = 0.104 %Cu t12 = 4.15 %Zn

t1 = 0.072 %Cu t2 = 0.342 %Zn

C1

C2

c21 = 1.10 %Cu c22 = 57.7 %Zn

Stream C1 T1 F

Weight% 4.426 95.574 100.00

%Cu 26.9 0.104 1.29

Cu units 119.059 9.940 128.999

%Recovery 92.29 7.71 100.00

Metallurgical Balances
Lets examine application of the 2-product formula Equations
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
t11 = 0.104 %Cu t12 = 4.15 %Zn

t1 = 0.072 %Cu t2 = 0.342 %Zn

Check assays of T1 balance

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 2.23 %Cu c22 = 57.7 %Zn

1. Zn assays in Circuit 1
Stream C1 T1 F Weight% 4.426 95.574 100.00

%Zn Zn units 9.25 40.940 (4.092) 391.060 4.32 432.000

%Recovery 9.477 90.523 100.000

So the Zn assay of T1 must be adjusted by -0.058 %Zn

Metallurgical Balances
Lets examine application of the 2-product formula Equations
Second step:
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
t11 = 0.104 %Cu t12 = = 4.092 4.15 %Zn t %Zn
12

t1 = 0.072 %Cu t2 = 0.342 %Zn

T1t12 = C2c22 + Tt2 T1 = C2 + T So C2 = 95.574(4.092 - 0.342) / (57.7 - 0.342) Stream C2 T T1 Weight% 6.249 89.325 95.574

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 1.10 %Cu c22 = 57.7 %Zn

%Zn 57.7 0.342 4.092

Zn units 360.570 30.550 391.120

(391.090)

%Recovery* 83.465 7.072 90.537

(90.530)

* with respect to F (4.32 %Zn)

Metallurgical Balances
Lets examine application of the 2-product formula Equations
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
t11 = 0.104 %Cu t12 = = 4.092 4.40 %Zn t %Zn
12

t1 = 0.072 %Cu t2 = 0.342 %Zn

Check assays of T1 balance

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 1.10 %Cu c22 = 57.7 %Zn

2. Cu assays in Circuit 2
Stream C2 T T1 Weight% 6.249 89.325 95.574

%Cu 1.10 0.072 (0.139)

Cu units 6.870 6.430 13.300

%Recovery 5.326 4.984 10.310

So the Cu assay of T1 must be adjusted by +0.035 %Cu

Metallurgical Balances
Lets examine application of the 2-product formula Equations
Return to Circuit 1: Ff1 = C1c11 + T1t11 100 = C1 + T1 So C1 = 100(1.29 - 0.139) / (26.9 - 0.139)
c11 = 26.9 %Cu c12 = 9.25 %Zn f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
= 0.139 0.139 %Cu %Cu tt11 11 = t12 = = 4.092 4.09 %Zn t %Zn
12

t1 = 0.072 %Cu t2 = 0.342 %Zn

C1

C2

c21 = 1.10 %Cu c22 = 57.7 %Zn

Stream C1 T1 F

Weight% 4.301 95.699 100.00

%Cu 26.9 0.139 1.29

Cu units 115.700 13.300 129.000

%Recovery 89.69 10.31 100.00

Metallurgical Balances
Lets examine application of the 2-product formula Equations
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
t11 = 0.139 %Cu t12 = 4.092 %Zn

t1 = 0.072 %Cu t2 = 0.342 %Zn

Recheck assays of T1 balance

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 2.23 %Cu c22 = 57.7 %Zn

1. Zn assays in Circuit 1
Stream C1 T1 F Weight% 4.301 95.699 100.00

%Zn Zn units 9.25 39.780 (4.098) 392.220 4.32 432.000

%Recovery 9.208 90.792 100.000

So the Zn assay of T1 must be adjusted by +0.006 %Zn

Metallurgical Balances
Lets examine application of the 2-product formula Equations
Return to Circuit 2:
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
tt11 = 0.139 0.104 %Cu %Cu 11 = tt12 4.15 %Zn %Zn 12 = 4.098

t1 = 0.072 %Cu t2 = 0.342 %Zn

T1t12 = C2c22 + Tt2 T1 = C2 + T So C2 = 95.699(4.098-0.342) / (57.7 - 0.342) Stream C2 T T1 Weight% 6.267 89.432 95.699

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 1.10 %Cu c22 = 57.7 %Zn

%Zn 57.7 0.342 4.098

Zn units 361.610 30.590 392.200

(392.175)

%Recovery* 83.706 7.081 90.787

(90.781)

* with respect to F (4.32 %Zn)

Metallurgical Balances
Lets examine application of the 2-product formula Equations
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
tt11 = 0.139 0.104 %Cu %Cu 11 = 4.40 %Zn t12 = 4.092 %Zn

t1 = 0.072 %Cu t2 = 0.342 %Zn

Check assays of T1 balance

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 1.10 %Cu c22 = 57.7 %Zn

2. Cu assays in Circuit 2
Stream C2 T T1 Weight% 6.267 89.432 95.699

%Cu 1.10 0.072 (0.139)

Cu units 6.890 6.440 13.330

%Recovery 5.341 4.994 10.330

So the Cu assay of T1 requires no further adjustment

Metallurgical Balances
Lets examine application of the 2-product formula Equations
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
=0.139 0.104%Cu %Cu tt 11= 11 =4.098 4.15 %Zn tt %Zn 12= 12

t1 = 0.072 %Cu t2 = 0.342 %Zn

Final Results: Stream Weight% C1 C2 T F 4.301 6.267 89.432 100.00 %Cu

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 1.10 %Cu c22 = 57.7 %Zn

%Zn

Units

Cu Zn 26.9 9.25 115.70 39.78 1.10 57.7 6.89 361.61 0.072 0.342 6.44 30.59 1.29 4.32 129.03 431.98

%Recovery Cu Zn 89.69 9.21 5.34 83.71 4.99 7.08 100.03 100.00

Metallurgical Balances
Lets examine application of the 3-product formula Equations
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
=0.139 0.104%Cu %Cu tt 11= 11 =4.098 4.15 %Zn tt %Zn 12= 12

t1 = 0.072 %Cu t2 = 0.342 %Zn

Three Product Results:

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 1.10 %Cu c22 = 57.7 %Zn

Stream Weight% C1 C2 T F 4.300 6.268 89.433 100.00

%Cu

%Zn

Units

Cu Zn 26.9 9.25 115.67 39.77 1.10 57.7 6.89 361.64 0.072 0.342 6.44 30.59 1.29 4.32 129.00 432.00

%Recovery Cu Zn 89.66 9.21 5.34 83.71 4.99 7.08 100.00 100.00

Metallurgical Balances
Lets examine application of the 3-product formula Equations
f1 = 1.29 %Cu f2 = 4.32 %Zn

T1
=0.139 0.104%Cu %Cu tt 11= 11 =4.098 4.15 %Zn tt %Zn 12= 12

t1 = 0.072 %Cu t2 = 0.342 %Zn

Difference between 2-Product and 3-Product: Stream Weight% C1 C2 T F 0.001 0.001 0.001 0.00 %Cu

C1
c11 = 26.9 %Cu c12 = 9.25 %Zn

C2
c21 = 1.10 %Cu c22 = 57.7 %Zn

%Zn

0.0 0.00 0.00 0.0 0.000 0.000 0.00 0.00

Units Cu Zn 0.03 0.01 0.00 0.03 0.00 0.00 0.03 0.02

%Recovery Cu Zn 0.03 0.00 0.00 0.00 0.00 0.00 0.03 0.00

Metallurgical Balances
The method relies on equations and tables Equations
3-Product Formula Bulk F = C1 + C2 + T Conc Ff1 = C1c11 + C2c21 + Tt1 Ff2 = C1c12 + C2c22 + Tt2 where F = feed tonnage rate or 100% C1 and C2 = concentrate1 and 2 tonnage or weight% T = tailing tonnage or weight% and f1, c11 , c21 , t1 = stream assay for element 1 (%, g/t, ppm, etc.) f2, c12 , c22 , t2 = stream assay for element 2 (%, g/t, ppm, etc.) C1 C2 F T

Three-Product Formula
Feed = Conc1 + Conc2 + Tailing Total Mass: F = C1 + C2 + T 4 unknowns + 4 unknowns + 4 unknowns = 12 unknowns - 1 variable

Element 1: Ff1 = C1c11 + C2c21 + Tt1 Element 2: Ff2 = C1c12 + C2c22 + Tt2

Let F = 100

Measure: f1, c11, c21, t1, f2, c12, c22, t2 - 8 variables ------------------------------------------------------------------------------------= 3 unknowns -------------------------------------------------------------------------------------

Three-Product Formula
Solution

C1 = 100(f1 - t1) (c22 - t2) - (f2 - t2) (c21 - t1) (c11 - t1)(c22 - t2) - (c12 - t2)(c21 - t1)

C2 = 100*(f1 - t1) (c12 - t2) - (f2 - t2) (c11 - t1) (c21 - t1)(c12 - t2) - (c22 - t2)(c11 - t1)

T = 100 - C1 - C2

Three-Product Formula
Problem: Equations for element 1 & element 2 and total mass must be
independent.

So: if f1 is similar to c11 is similar to c21 is similar to t1 then Element 1 equation is same as Total Mass equation.

And: if Element 1 is associated with Element 2 (Ag dissolved in Cu minerals) then Element 1 equation is same as Element 2 equation. Association may be due to interlocked minerals. The 3 equations are reduced to 2 and an incorrect solution is obtained. An answer may be obtained, but it is likely wrong.

Three-Product Formula
The reason an answer may be obtained is because of measurement errors from 1. 2. 3. 4. Sampling, Sample preparation, Contamination, and Non-steady-state conditions in the process during sampling . Analytical lab results are usually very accurate, although mistakes do occur and "strange" assays can occur.

Metallurgical Balances
Process Disturbances leading to variation in results Mineralogy changes (quality & quantity) Liberation changes (locking characteristics) Particle size changes (coarse and ultra-fines) Water chemistry changes (pH and ions and S.S.) Process control of flow rates Reagent addition control (quantity & quality) Poor house-keeping issues Equipment mal-functions Planned maintenance interruptions Temperature and pressure changes Moisture changes

Metallurgical Balances
First step What is the purpose of the sample and the balance? Evaluation of lab testwork Evaluation of plant testwork Accounting purposes Process control Two important sampling issues: Accuracy (representativeness and processing) Turn-around time

Metallurgical Balances
Second step How should the sample be taken? Grab samples Composite samples Method used Water versus solids Two sampling issues: Manual techniques proper training Automated methods proper maintenance

Metallurgical Balances
Third step How should the sample be prepared? Sub-sampling (riffle-splitting) Cone & quartering Dewatering Weighing Size reduction Two sampling issues:

Retention of sample make-up Avoiding contamination

Metallurgical Balances
Fourth step How should the sample be assayed and stored? Assay tolerances Duplicates or triplicates Automated (self-assayed) Use of an assay lab Method of assay (A.A., XRF, GC, fire-assay, etc.) Two assaying issues:

Sample retention for future examination Sample degradation (oxidation/moisture pick-up)

Metallurgical Balances
Fifth step How should the results be reported? Qualified person (public release) Chain of custody issues (samples and data) Some samples submitted as blanks and surrogates

Two reporting issues:

Security of data Reliability of results and interpretation

Metallurgical Balances
Analytical Errors: 1. 2. 3. 4. 5. 6. 7. 8. 9. Sampling Errors Sample Preparation Errors Assay Errors Human Communication Errors Weighing Errors Noisy Data Errors Unstable Process Errors Time Delay Errors Particle Size Errors

Metallurgical Balances
Minimize the Impact of Errors

Sampling - sample part of the stream, all of the time - sample all of the stream, part of the time - ensure cross sample contamination cannot occur - ensure pulp sampler does not overflow - ensure that segregation of particles does not occur
Assaying - different labs may produce different results - a well-run lab does not make many mistakes - assay involves at least three sub-samples - agreement must meet rigid variance standards

Metallurgical Balances
Minimize the Impact of Errors

Sample Preparation (for the Assay Lab) - Samples must be filtered and dried and recovered - Samples must be bucked - Samples must be less than 100 microns in size - Samples must be bagged and properly labelled - Most cross-contamination occurs at this stage
Human Communication - Mistakes on where sample is taken - Mistakes on how sample is prepared - Mistakes in reporting results - Rush samples can lead to poor quality

Metallurgical Balances
Minimize the Impact of Errors

Weighing Errors - part of sample is lost during processing and/or testing - calibration of instruments not done well - in lab, tare weights must be properly accounted for - improper dewatering - improper compositing
Process Issues - unbalanced dynamic effects - steady-state balances can be done, but are meaningless - inaccurate sampling may result - on-line assays are timely, but less-accurate

Metallurgical Balances
Minimize the Impact of Errors

Particle Size Errors - Low-grade gold oresthe Nugget effect - Coarse size distributions lead to settling and segregation - Non-representative samples - Samples must be reduced in size for assaying - Ultra-fines may require Cyclosizer analysis
Reporting Issues - In production accounting, material must be written-off - Errors accumulate due to moisture pick-up and losses - Stockpiles must be accurately measured and sampled - Sampling railcars is an art-form