Comminution, Mineral Separation and Continuous Bulk Handling
Comminution, slurry hydraulic transport and bulk materials handling calculations including ball mill charge, flotation kinetics, hydrocyclones and belt conveyors.
Adheres to Bond, Hogg & Fuerstenau, and Austin comminution kinetics. Accurately calculates overflow/grate ball mill critical rotational speed, operating speed ratio, media filling degree J, total ball charge tonnage, maximum make-up ball diameter, and shaft drive power.
Calculate ball mill grinding media charge, critical speed and power draftApplies multiphase hydrodynamics and Garcia-Zuniga froth flotation kinetics. Accurately determines slurry volume flow, superficial gas velocity Jg, hydraulic retention time tau, series bank flotation recovery R, forced air flow, and impeller motor power.
Calculate flotation cell superficial gas velocity, residence time and recovery kineticsCalculate industrial hydrocyclone classification cut size d50, underflow and overflow discharge rates, solid concentration, vortex finder and apex (spigot) throat dimensions based on Bradley cyclone dynamics and centrifugal sedimentation mechanics.
Calculate hydrocyclone desander cut size d50 and flow throughputCalculates hydrocyclone radial manifold riser velocity, radial branch dynamic head loss, branch flow imbalance (within ±3%), and required slurry feed pump head in accordance with mineral processing and solid-liquid separation engineering standards.
Size hydrocyclone cluster manifold radial distributor and slurry pressure dropCalculates slurry pipeline Durand critical deposition velocity VL, operating velocity margin ratio, clear water and slurry hydraulic gradients, total line pressure drop, and slurry pump shaft power based on Durand-Condolios and Wasp multiphase flow models.
Calculate slurry pipeline critical settling velocity and Durand friction head lossFollow ISO 5048 and CEMA standards to calculate heavy apron feeder conveying capacity (t/h), dump hopper ore column shear resistance, total chain pull tension (kN), and drive motor installed power (kW).
Calculate heavy duty apron feeder capacity and chain pull powerCalculate bulk port and coal stockyard bucket wheel stacker reclaimer theoretical and actual capacity t/h, bucket cutting speed, wheel drive shaft power, and slewing boom torque based on ISO 5048 and DIN 22261.
Calculate bucket wheel stacker reclaimer capacity and motor powerCalculate belt conveyor motion resistances, drive pulley traction Fu, shaft power, and motor rating per ISO 5048 and CEMA standards. Inputs capacity in t/h, length, lift height, belt width, velocity, idler friction factor, and drive efficiency.
Calculate belt conveyor power and resistanceCompliant with German industrial standard DIN 22101 and CEMA continuous bulk handling standards, enter conveyor horizontal center distance (m), belt width (mm), design belt speed (m/s), drive motor total power (kW), drive pulley wrap angle (180°–240°), pulley lagging surface type, and take-up mechanism (vertical gravity / tail carriage gravity / manual screw). Based on Euler-Eytelwein friction drive equations, accurately compute peripheral driving force Te (kN), tight-side tension T1, slack-side slip-prevention tension T2, and idler sag limit tension. Outputs required counterweight mass (kN & metric tons) and trolley take-up design travel (m) accommodating both elastic elongation and permanent plastic carcass creep.
Calculate belt conveyor take-up travel and counterweightCalculate belt conveyor terminal pulley transition distance Ltr, belt edge localized tension increase, intermediate transition idler stages, and pulley elevation profiles based on CEMA 7th, DIN 22101, and ISO 5048 standards.
Design belt conveyor transition distance and idler alignmentCalculates screw conveyor operating speed (RPM), volumetric throughput, incline derating factor, friction drive power, shaft horsepower, and recommended motor size per CEMA Standard 350 and ISO 7149.
Calculate screw conveyor capacity and powerCompliant with DIN 15201 and CEMA 350 vertical bulk handling standards, enter bucket geometric volume (L), bucket pitch spacing (mm), traction linear speed (m/s), vertical lift height (m), bulk density (t/m³), and filling factor (%). Select bucket profile (deep bucket, shallow bucket, or continuous overlapping bucket) to compute volumetric capacity (m³/h), mass throughput (t/h), net vertical lifting power (kW), terminal head shaft brake power (kW), recommended motor kW, and peak dynamic belt/chain tension (kN).
Calculate bucket elevator capacity and drive motor powerCompliant with ISO 7539 industrial screening equipment standards and CEMA bulk material handling formulas. Enter feed throughput rate (t/h), loose bulk density (t/m³), aperture separation cut size (mm), percentage of half-size fines (<0.5d) and oversize particles (%), deck incline angle (0°–25°), screening media (woven wire/polyurethane panel/perforated plate), and process condition (dry screening/wet spray). Uses multi-factor passage kinetics to calculate required net screening deck area (m²), recommend standardized screen dimensions (width × length at 2.0–2.5 aspect ratio), evaluate bed velocity and feed-end bed depth against stratification limits, and compute dual vibration motor drive power (kW).
Calculate vibrating screen capacity and motor powerStart with the Ball Mill Media Charge Calculator to verify critical speed and volume filling degree, cross-check classification cycloning with the Hydrocyclone Cluster tool, and evaluate bank retention time with the Flotation Kinetics Calculator.
Begin by establishing capacity and lump size limits, calculate drive traction and motor power via the Belt Conveyor Power Calculator, evaluate transition idler stresses along convex curves, and determine gravity counterweight requirements.
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Already have an account? Open your workspace →Optimal media charge filling typically ranges between 30% and 45%. Under-charging leads to ball-on-liner impacts that cause premature shell failure, while over-charging impairs cascading trajectory kinetics and dampens grinding efficiency.
Operating below critical settling velocity triggers solids deposition and catastrophic pipe sanding. The operating slurry velocity must maintain a 15% to 35% safety margin above Durand velocity to prevent blockages without accelerating abrasive erosive wear.
Cluster manifolds maintain uniform dynamic pressure across symmetrical radial branches. The tool balances branch velocities between 3.0 and 4.5 m/s to ensure equal slurry split, preventing short-circuit roping and misplaced coarse particles.
