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About the BallParam_Open Spreadsheet ...
Scope :
The BallParam_Open spreadsheet was designed to be used - in conjunction with the Ball Mill Grinding Simulators
BallSim_Direct, BallSim_Reverse or BallSim_Dual - in the "tuning" of such simulators to any specific actual grinding
system, via the estimation of the various Model Parameters that characterize the grindability of any given ore. In other
words, the attached spreadsheets provide an effective algorithm to search for the set of parameter values that best
approximate the model response to the actual experimental measurements available (obtained from Continuous, Pilot
or Full Plant Scale Mills), based on a typical non-linear, least-squares criterion.
Theoretical Framework :
The reference ball mill model is described with further details in the About ... worksheets of the BallSim_Direct,
BallSim_Reverse or BallSim_Dual files.
Such model is based on the so called Modern Theory of Comminution. This theory introduced two new sets of
parameters : the Selection Function S and the Breakage Function B. The first set also referred to as Grindability
relates to the grinding kinetics of each independent particle and the second set also referred to as Distribution of
Primary Fragments characterizes the size distribution of the fragments produced as a result of breakage events.
The size-dependence of the Selection and Breakage Parameters is represented by the following relationships :
An expanded form of this expression - also available in this simulation routine - is given by :
An expanded form of this expression - also available in this estimation routine - is obtained by replacing b0 in
Equation 2 by :
These expanded forms for Si and Bij are intended to provide the model greater descriptive flexibility when tuning
the model to actual specific grinding systems but, since they increment the total number of ore characteristic
parameters to be estimated, its use should be avoided whenever possible. In any case, the proposed expanded
forms reduce to the normal forms if a02 and b01 are set equal to zero.
On the basis of Pilot or Industrial Scale Data, like those typically obtained from plant sampling or audit campaigns, the
BallParam_Open routine allows for the calculation of all a's and b's (including dcrit) that minimize the least-squares
Objective Function :
where the fi's represent the experimental size distribution of the mill product (as % retained on screen 'i' ) and the fi's
represent the model response for each corresponding fi, for a given set of model parameters. The a's and b's (including
dcrit) that yield the minimum possible value of f are so considered to be representative of the particular ore under analysis.
Also in Equation 3, the wi's represent user defined Weighting Factors that quantify the relative quality and reliability of
each particular mesh value with respect to the other screens data. Relatively high values of such weighting factors
indicate more reliable measurements. At the extreme, a w i factor equal to zero means that this particular measurement is
not being included in the Objective Function.
The minimization problem stated above may be readily solved with the aid of the Excel Subroutine Solver.
Most of the data required by the algorithm must be defined in each corresponding unprotected white background cell -
inside the red double-lined border - 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.
The remaining information required to run the program is entered in the Control_Panel worksheet, where the user is
requested to provide initial guesses of the grinding parameters listed above.
To run the program, select the objective function Cell E27 in Control_Panel and then, from the Tools Menu, select
Solver ..., then Min and then By Changing any combination of Cells E10:E24 (see Useful Hints below). Clicking on the
Solve button will execute the desired calculations.
Important Notice : Solver ... must be run every time any element of input data gets to be modified. Otherwise, the
current outputs are not valid.
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. Eventually, the user may wish to remove the view of the comments by
selecting Tools / Options / View / Comments / None.
Useful Hints :
The proper utilization of the parameter estimation spreadsheets - like BallParam_Open - is by far the most complex task
to be undertaken with Moly-Cop Tools. There is no set of firm recommendations to obey, but the following hints may
help guiding the user in the search of the most representative set of grinding parameters :
1. It is not required to run the Solver search for all parameters at the same time. In fact, this is strongly not
recommended, as the search algorithm will most likely fail to find the minimizing optimum when dealing with too many
parameters at once. To exclude any given parameter off the search, remove the corresponding cell reference (in the
E10:E24 range in Control_Panel) off the By Changing list of cells in Solver and that parameter value will then remain
constant and equal to its original guess during the whole search.
2. When multiple experimental data sets are available (the most desirable condition) for various ore types (hard, soft,
etc.) or grinding conditions (mill filling, ball size, % solids, etc.), always attempt to obtain a reasonable model fit of these
data with the same average parameter values for all sets. If that is not acceptable, proceed to allow differences in the
most critical parameters in the following sequence : a0, dcrit, b0, a1and b1. Keep in mind that a larger number of adjustable
parameters in the search (that is, included in the By Changing list) will necessarily yield lower Objective Function (Cell
E27) values, but the values of the parameters that achieve such minimum will be less reliable in statistical terms and
therefore, from one data set to another, these parameters will exhibit significant variability and covariance amongst them,
rendering them meaningless.
3. An advisable starting run of the algorithm for each independent available data set should considered a search for
parameters a0, a1, dcrit and b0; leaving the others fix at nominal values : a2 = 3.0, b1 = 0.5 and b2 = 4.0. Use the
green background table below the Control_Panel area to summarize the results of your search with the various
available data sets. Be careful to follow the instructions provided at the bottom of such table. If the model fits
appear to be reasonable, then you should attempt to reduce the number of adjustable parameters. Look for the one
parameter that exhibit the least Coefficient of Variation (the ratio of its standard deviation to its average value, for all
data sets) and set it fix at its average value and equal for all data sets, for the next runs of the search. Continue removing
the remaining adjustable parameters off the By Changing list, one at a time, until the model fit is no longer judged
acceptable. The concept behind this parameter screening process is to lump the impact of whatever ore properties or
process variable are being investigated into the least possible number of parameters in order to improve the statistical
significance of the estimations and facilitate the derivation of valid conclusions regarding such effects. For instance, it is
believed that the distribution of ball sizes in the mill only affects the parameters a0 and dcrit. Similarly, hardness variations
of the same ore source may be well described by changes in the a0 parameter only. Not all grinding systems require a
finite value of dcrit; whenever the estimated value of this parameter tends to be greater than the top mesh opening, set it
fix at 100,000 and remove it from the By Changing list.
4. If the step above does not provide satisfactory model fits, then you should add b1 to the list of adjustable parameters
and eventually, include b01, a02 and a12 (one at a time, in that order). If the model fits are still not satisfactory, there is a
good chance the data contains significant experimental errors and should be discarded.
5. Never run a search for a2 or b2, as these parameters have little effect on the objective function and may just confuse
the search algorithm. When in doubt, simply try assigning them values between 2 and 4 and observe the response of the
Objective Function (Cell E27). In other words, these two parameters are better optimized by a very basic trial-and-error
procedure, not via the Solver routine.
Test N 1
100.00
SELECTION FUNCTION :
alpha0 0.014847
alpha1 0.570
alpha2 2.5
Dcrit 6459
% Passing
Expanded Form
alpha02 0.0000000 10.00
alpha12 1.000
BREAKAGE FUNCTION :
Objective Function 0.06 Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
% Solids (by weight) 72.0 Charge Mill Charge Weight, tons Apparent Mill Flowrate, tph (dry) 1622.8
Ore Density, ton/m3 2.80 Volume, Ball Slurry Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial Excess ton/m3 Total Energy, kWh/ton 2.39
Balls Density, ton/m3 7.75 63.76 296.48 47.48 0.00 5.395 Balls Energy, kWh/ton 2.06
Make-up Ball Size, mm 75.00
Feed Size Distributions Objective Function
Mill Feed Mill Disch. (exp) Mill Disch. (adj) % Passing % wi wi (error)^2
i Mesh Opening Mid-Size % Ret % Pass % Ret % Pass % Ret % Pass Exp Adj. Error
MODEL PARAMETERS
Selection Breakage
alpha01 0.014847 beta00 0.20000
alpha02 0.0000000 beta01 0.000
alpha11 0.570 beta1 0.250
alpha12 1.000 beta2 4.000
alpha2 2.500
Dcrit 6459 Obj. Function 0.06
Ebar 2.06 N
Matrix J
1 2 3 4 5 6
1 0.679702746 0 0 0 0 0
2 0 0.5058272039 0 0 0 0
3 0 0 0.3315940031 0 0 0
4 0 0 0 0.2162174852 0 0
5 0 0 0 0 0.1525746918 0
6 0 0 0 0 0 0.135526842
Page 9
Model
7 0 0 0 0 0 0
8 0 0 0 0 0 0
9 0 0 0 0 0 0
10 0 0 0 0 0 0
11 0 0 0 0 0 0
12 0 0 0 0 0 0
13 0 0 0 0 0 0
14 0 0 0 0 0 0
15 0 0 0 0 0 0
16 0 0 0 0 0 0
17 0 0 0 0 0 0
18 0 0 0 0 0 0
19 0 0 0 0 0 0
20 0 0 0 0 0 0
Matrix T
1 2 3 4 5 6
1 1 0 0 0 0 0
2 0.788034333 1 0 0 0 0
3 0.433958772 0.7838570203 1 0 0 0
4 0.326435204 0.6757543812 1.3021093077 1 0 0
5 0.252443705 0.5857216002 1.4832822357 2.1061904263 1 0
6 0.238743318 0.6167787291 1.9997408865 4.6589631632 7.5705992388 1
7 0.262524922 0.7662365658 3.3025554762 14.052211181 218.7736181 -11.601064795
8 0.309031068 1.0490517584 6.5695746529 75.163030151 -1376.3364104 38.575723721
9 0.428816124 1.7649212251 19.076498645 -3846.976766 3123.63341 -62.196733933
10 0.574055347 3.1134751124 90.524857473 12462.771124 -3426.0936765 53.162995912
11 0.884284794 7.0507241975 50025.594707 -17560.92285 2062.7881133 -25.09266449
12 1.447815092 21.486195063 -175184.90769 13284.173286 -732.44838884 6.9976973278
13 2.690749622 130.77202555 250348.21193 -5617.561823 135.13593546 -0.9424125741
14 5.941025285 -2219.1459832 -187796.03695 1304.0365921 -10.876060085 0.0463633485
15 17.59110478 5919.7770453 78366.491383 -136.1370157 -0.2606908462 0.0050389078
16 97.61469144 -7076.2378528 -17599.378523 3.4223999097 -0.2376811741 0.0037803484
17 -2687.3386 4550.0910305 1794.6795389 0.9306384579 -0.2174241343 0.0033979384
18 7856.55558 -1630.4827252 -33.246399558 0.7730260762 -0.2006677061 0.0031288952
19 -9839.39161 303.39828678 -4.7805710677 0.6725588023 -0.17647136 0.0027510577
20 4539.390918 -17.064542556 -41.88603946 7.8384339725 -2.0542049961 0.0319983357
Vector SiE
1 2 3 4 5 6
1 0.197273628 0.3628097598 0.62363763 0.9200066059 1.1883743744 1.2855082891
Page 10
Model
Matrix bij
1 2 3 4 5 6
1 0 0 0 0 0 0
2 0.661254908 0 0 0 0 0
3 0.121199143 0.5635233113 0 0 0 0
4 0.051285933 0.2040574151 0.6187965309 0 0 0
5 0.021839227 0.06035874 0.163024186 0.6143799633 0 0
6 0.014141521 0.0248564278 0.0516886781 0.1674407536 0.6187965309 0
7 0.011436325 0.0149373601 0.022246279 0.0517866333 0.1645416049 0.6197279266
8 0.009480048 0.0110361085 0.0133437524 0.0211307441 0.0488441586 0.1584161657
9 0.009574967 0.0107505519 0.0119776531 0.0149289713 0.0235733796 0.055463258
10 0.007864554 0.0087376042 0.0094876432 0.0107637144 0.0133437524 0.0211307441
11 0.007667902 0.0084953584 0.0091604226 0.0101097615 0.0114644737 0.0143299053
12 0.006959904 0.0077047306 0.0082910314 0.0090754422 0.0100008227 0.0113627804
13 0.006446056 0.0071343232 0.0076729658 0.0083799994 0.0091604226 0.0101097615
14 0.005890368 0.0065189096 0.0070100244 0.0076512389 0.0083452155 0.0091346577
15 0.005382082 0.0059562892 0.0064047545 0.0069894331 0.0076187817 0.008320784
16 0.00495316 0.0054815822 0.0058942395 0.0064320205 0.0070100244 0.0076512389
17 0.004525766 0.005008586 0.0053856194 0.0058769214 0.0064047545 0.0069894331
18 0.004165093 0.0046094337 0.0049564159 0.0054085455 0.0058942395 0.0064320205
19 0.003665972 0.0040570655 0.0043624663 0.0047604109 0.0051878845 0.0056611487
20 0.042267071 0.046776203 0.0502973374 0.0548854464 0.0598139545 0.0652701756
1 1 1 1 1 1
Page 11
Model
Matrix J
1 2 3 4 5 6
1 0.679702746 0 0 0 0 0
2 0 0.5058272039 0 0 0 0
3 0 0 0.3315940031 0 0 0
4 0 0 0 0.2162174852 0 0
5 0 0 0 0 0.1525746918 0
6 0 0 0 0 0 0.135526842
7 0 0 0 0 0 0
8 0 0 0 0 0 0
9 0 0 0 0 0 0
10 0 0 0 0 0 0
11 0 0 0 0 0 0
12 0 0 0 0 0 0
13 0 0 0 0 0 0
14 0 0 0 0 0 0
15 0 0 0 0 0 0
16 0 0 0 0 0 0
17 0 0 0 0 0 0
18 0 0 0 0 0 0
19 0 0 0 0 0 0
20 0 0 0 0 0 0
Matrix T
1 2 3 4 5 6
1 1 0 0 0 0 0
Page 12
Model
2 0.788034333 1 0 0 0 0
3 0.433958772 0.7838570203 1 0 0 0
4 0.326435204 0.6757543812 1.3021093077 1 0 0
5 0.252443705 0.5857216002 1.4832822357 2.1061904263 1 0
6 0.238743318 0.6167787291 1.9997408865 4.6589631632 7.5705992388 1
7 0.262524922 0.7662365658 3.3025554762 14.052211181 218.7736181 -11.601064795
8 0.309031068 1.0490517584 6.5695746529 75.163030151 -1376.3364104 38.575723721
9 0.428816124 1.7649212251 19.076498645 -3846.976766 3123.63341 -62.196733933
10 0.574055347 3.1134751124 90.524857473 12462.771124 -3426.0936765 53.162995912
11 0.884284794 7.0507241975 50025.594707 -17560.92285 2062.7881133 -25.09266449
12 1.447815092 21.486195063 -175184.90769 13284.173286 -732.44838884 6.9976973278
13 2.690749622 130.77202555 250348.21193 -5617.561823 135.13593546 -0.9424125741
14 5.941025285 -2219.1459832 -187796.03695 1304.0365921 -10.876060085 0.0463633485
15 17.59110478 5919.7770453 78366.491383 -136.1370157 -0.2606908462 0.0050389078
16 97.61469144 -7076.2378528 -17599.378523 3.4223999097 -0.2376811741 0.0037803484
17 -2687.3386 4550.0910305 1794.6795389 0.9306384579 -0.2174241343 0.0033979384
18 7856.55558 -1630.4827252 -33.246399558 0.7730260762 -0.2006677061 0.0031288952
19 -9839.39161 303.39828678 -4.7805710677 0.6725588023 -0.17647136 0.0027510577
20 4539.390918 -17.064542556 -41.88603946 7.8384339725 -2.0542049961 0.0319983357
Matrix T (inverse)
1 2 3 4 5 6
1 1 -1.502053E-16 5.3438428E-17 -1.87757E-17 -2.021995E-17 -1.408175E-17
2 -0.78803433 1 1.6141743E-15 1.29887E-15 1.8759308E-15 1.7930945E-15
3 0.183747472 -0.7838570203 1 8.704484E-16 -7.713071E-17 -6.230333E-16
4 -0.03317684 0.3449131408 -1.3021093077 1 4.4234195E-15 8.4059167E-15
5 0.006452417 -0.1494931618 1.2592079221 -2.106190426 1 -1.78399E-14
6 -0.0144268 0.4755474027 -5.466220124 11.286160475 -7.5705992388 1
7 -1.37831729 35.197718547 -323.90048739 577.65816773 -306.6006304 11.601064795
8 4.332746948 -69.497006139 411.74309895 -513.9145413 131.57643436 19.573314248
9 -119.426687 1193.0673694 -4312.4739075 3132.8589743 70.735786056 24.065612124
10 -46.2134409 297.45134149 -648.013354 201.23500539 50.852188718 25.424946478
11 -9283.73011 39727.856207 -50905.309385 105.20874011 45.03266395 28.035712662
12 155.940272 -440.45489193 293.57880919 69.285915383 39.21513322 28.2110068686
13 291.049779 -532.5739874 128.65016017 53.41020787 35.847619269 28.43617685
14 -1144.2504 1287.5635123 80.053784653 44.12292252 33.163680125 28.174393652
15 -336.578694 207.84094306 58.788409366 38.464062927 31.2612111964 27.885326846
16 -433.331154 105.50892401 47.128057398 34.549364832 29.688746248 27.431053682
17 1942.554827 69.859884334 39.815672255 31.594809754 28.268957646 26.792994009
18 213.2466766 52.706447531 34.979746496 29.381843635 27.07792778 26.140353305
19 107.6163466 43.654180441 32.058038888 28.054602712 26.414252394 25.832207871
20 1 1.0000000001 0.9999999999 1 1 1
Page 13
Model
Matrix T*J
1 2 3 4 5 6
1 0.679702746 0 0 0 0 0
2 0.5356291 0.5058272039 0 0 0 0
3 0.294962969 0.3964962049 0.3315940031 0 0 0
4 0.221878905 0.3418149492 0.4317716378 0.2162174852 0 0
5 0.171586679 0.2962739193 0.4918474943 0.4553951974 0.1525746918 0
6 0.162274489 0.31198346 0.6631020858 1.0073492989 1.1550818456 0.135526842
7 0.17843891 0.3875832996 1.0951075909 3.0383337633 33.379317356 -1.5722556756
8 0.210049266 0.5306389177 2.178431558 16.251561361 -209.99410364 5.2280460142
9 0.291467497 0.8927451684 6.3256525514 -831.783642 476.58740483 -8.4293269333
10 0.390186996 1.5748804106 30.017499872 2694.6690313 -522.73518679 7.2050129478
11 0.601050803 3.5664481064 16588.187208 -3796.978577 314.72926065 -3.400729576
12 0.984083894 10.868301971 -58090.264828 2872.2705411 -111.75308719 0.9483758202
13 1.828909907 66.148048036 83013.965769 -1214.61509 20.618323705 -0.1277222
14 4.0381312 -1122.5044078 -62272.039665 281.95551258 -1.6594115155 0.0062834782
15 11.95672222 2994.3842706 25985.858589 -29.43520318 -0.0397748255 0.0006829073
16 66.34897382 -3579.3536073 -5835.848377 0.7399827019 -0.0362641319 0.0005123387
17 -1826.59143 2301.5598235 595.10497263 0.201220307 -0.0331734203 0.0004605119
18 5340.122402 -824.74251794 -11.024306719 0.1671417542 -0.0306168134 0.0004240493
19 -6687.8615 153.46710708 -1.5852086976 0.1454189729 -0.0269250634 0.0003728422
20 3085.436473 -8.631709847 -13.8891595 1.6948064816 -0.3134196942 0.0043366334
Matrix [T*J*T(inv.)]
1 2 3 4 5 6
1 0.679702746 -1.02095E-16 3.6322247E-17 -1.27619E-17 -1.374355E-17 -9.571403E-18
2 0.137019897 0.5058272039 8.4511644E-16 6.469472E-16 9.3806643E-16 8.9945337E-16
3 0.043439907 0.1365739176 0.3315940031 7.980945E-16 7.1225922E-16 5.0020745E-16
4 0.024680522 0.0779439716 0.1502328379 0.2162174852 1.5598526E-15 2.1582801E-15
5 0.014364292 0.0449987227 0.0909964298 0.1340438422 0.1525746918 1.3284911E-15
6 0.010341322 0.0314268459 0.0650918472 0.1041046616 0.1290624387 0.135526842
7 0.008450676 0.0244557594 0.0508358168 0.0853097748 0.116853738 0.1366987827
8 0.007081022 0.0192963398 0.0395350753 0.0676645483 0.0979258808 0.1259887724
9 0.006827061 0.0173428405 0.0343304721 0.0581568932 0.0856386178 0.1149937527
10 0.005767288 0.0137140566 0.0260019587 0.0427729551 0.0625094358 0.0849822433
11 0.005447044 0.01224172 0.0221386943 0.034759556 0.0490898887 0.0653852857
Page 14
Model
Page 15
Model
akage Function :
6.5595708128
9.0734782404
3.6901957891
7 8 9 10 11 12
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
Page 16
Model
0.1473101382 0 0 0 0 0
0 0.1769698036 0 0 0 0
0 0 0.2204320704 0 0 0
0 0 0 0.2733806497 0 0
0 0 0 0 0.3311306474 0
0 0 0 0 0 0.3937791538
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
7 8 9 10 11 12
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
1 0 0 0 0 0
-5.0123880003 1 0 0 0 0
10.196847914 -4.0955338748 1 0 0 0
-10.35332899 6.5006010151 -3.5617879969 1 0 0
5.7929697276 -5.4276710254 5.3229567302 -3.6189010988 1 0
-1.9148659162 2.6201476676 -4.2206209829 5.2939155343 -3.4707477243 1
0.3229657107 -0.6926597518 1.8688335042 -4.0591011373 4.9332914694 -3.4654345755
-0.0226963133 0.0916691939 -0.4565433978 1.7466353903 -3.6843471593 4.8901181768
-0.0009362455 -0.0027944603 0.0514427723 -0.4053565486 1.5308141951 -3.6140429003
-0.0007150931 0.0004199577 -0.001489284 0.0428008345 -0.3420771781 1.4895067935
-0.0006456862 0.0004702041 -0.0002704364 -0.0008145768 0.034625126 -0.3318116423
-0.0005950506 0.0004404976 -0.0002111747 3.342228E-05 -0.0006261792 0.0327914135
-0.0005232144 0.0003879933 -0.0001826335 5.9165683E-05 -9.425063E-05 -0.0005728251
-0.0060888424 0.0045225829 -0.0021271003 0.0007290144 -0.0008382991 -0.0005544406
7 8 9 10 11 12
1.2168365421 1.0710918001 0.9058741277 0.7531860512 0.6245518599 0.5138611317
Page 17
Model
7 8 9 10 11 12
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0.6003511321 0 0 0 0 0
0.1814695849 0.6317428388 0 0 0 0
0.0497794672 0.1500778782 0.6003511321 0 0 0
0.0230406762 0.0516113619 0.1772844553 0.6180603258 0 0
0.014231306 0.022021565 0.0539645967 0.1637603912 0.6151284108 0
0.0114974978 0.0141427248 0.0230406762 0.0516113619 0.1666923061 0.6180603258
0.0100853417 0.0113594544 0.0143159038 0.0221341356 0.0515132953 0.1643283375
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Page 29
Model
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Model
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Model
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Model
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Model
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Page 34
Model
19 20
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Mill Mill
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Model
100.00 100.00
Page 36
Model
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1 1
Page 37
Model
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Page 38
Model
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Page 39
Model
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Page 40