EQUIPMENT DESIGN:

1). Ball Mill:

Feed Rate = 218 ton/hr
= 218000 kg/day
= 9083.333 kg/hr
Feed

Tons/hr Fraction Density

Kg/m3
Rock 8992.50 99%
2740
Water 90.83
1%
1000

Average Density
Kg/m3
2712.6
10

Sav = 2722.6 kg/m3

Volumetric Flow rate = 9083.333 kg/hr * m3/2722.6 kg
= 3.3363 m3/hr
Power Calculations:
P = 0.3162 Wi m (1/Dp 1/Df)
Df = feed size = 25.4 mm
Dp = product size = 0.08 mm
Wi = work index = 13.23 Kwh/ton
M = 9.0833 ton/hr
So,
P = 126.8 Kw
Efficiency = 70%

P = 181.14 Kw
= 242.8 hp
Grinding Time:
Sx = E * 100 / Wi * Wt * 60
E = 242.8
Wi = 13.23 Kwh/ton
Wt = 9083.333 Kg/hr
So,
Sx = 0.0336
Time for grinding
1/Sx * Dxy/Xy = - dt
t = 60 minutes
= 1 hr
Volume of Mill:
Total feed rate = 3.33633 m3/hr
Grinding time = 1 hr
Volume of void space required = 3.33633 m3/hr
With material to grind Void space occupied by balls = 41%
Volume occupied by balls = 3.363/0.41
= 8.137 m3
As balls should occupy half of mill

Volume of ball mill = 8.137 * 2

= 16.275 m3
For closed loop grinding
L/D = 1
V = 3.14/4 * D2L
= 3.14/4 D3
D = 2.75
= 8 ft.
Critical speed:
N = 42.3/D1/2
= 25.5 RPM
Operating Speed:
No = 0.75 * 25.5
= 19.13 RPM
Maximum Diameter of Balls:
B = F/K * [S Wi/100CsD1/2] 1/3
B = Maximum size of balls
F = Feed size
= 25400 micron meters
K = constant = 330
Cs = Fraction of critical speed = 0.75
D = Diameter of balls
= 4 ft.
So, B = 4 inches.
Weight of Ball Mill:

Density of balls = 290 lb/ft3

= 4646 Kg/M3
Weight of balls = 290 * 3.14 (D2/2) * 2.75 * 0.41
= 3882.2 lb
= 1764 kg

2). REACTOR:

Total mass flow rate entering the reactor = 508 tons/day

= 21166.67 kg/hr
Total volume entering the reactor = 14.826 m3/hr
Residence time = 1 hr
Take 30% excess volume for safety
So, volume of reactor = 19 m3
Geometry of cylindrical shell:
H/D = 2
Volume = 3.14/4 * D2 * H
So, D = 2.295 m
H = 4.59 m
Thickness = PiDi/2JF Pi + Cc
Di = 2.295 * 103 mm
Pi = 1424.6 * 9.8 * 4.59
= 64085.18 N/m2
= 0.0640 N/mm2
Design pressure = 10% excess
= 0.0794 N/mm2
f = 125 N/mm2
J=1
Cc = corrosion allowance
= 0.5 mm/yr
Ts = 10.65 mm
= 11 mm

Geometry of Header:
Proposed headers are flanged and standard dished torrispherical
t = 1/8 + ts
= 0.546 inches
Sf = 3 inches
i.c.r = 3t = 1.638 inches
r = dish radius = shell radius
= 89.505 inches
AB = I.D/2 i.c.r
= 89.505/2 1.638
= 46.39 inches
BC = r i.c.r
= 89.505 1.638
= 87.867 inches
b = r (BC2 AB2)0.5
= 89.505 (87.867 2 146.39 2)0.5
b = 10.882 inches
So, height of header = OA
= t + b + Sf
= 0.546 + 10.882 + 3
= 14.43 inches.
Maximum bolt spacing:
BS = 2d + ( 6 t/m + 0.5 )
m = gashet factor
= 2.5
d = bolt diameter

= 1 inch
t = flange thickness
= 3/4 inch
BS = 4.3 inch
No. of bolts = dish radius/maximum bolt spacing
= 89.505/4.3
= 21 bolts
Geometry of impeller:
Inside diameter of tank = 2.295 m
Baffle width = 0.05 D = 0.1836 m
Diameter of impeller = D/3
= 0.765 m
off wall clearance = 0.02 D
= 0.0459 m
off bottom clearance = 0.2d = 0.5355m
width of blade/ dia. Of impeller = 0.125
So,
Width of blade = 0.0956 m
Length of blade/dia. Of impeller = 0.25
So,
Length of blade = 0.19128 m
Angle of blade = 90
Power calculation for agitator:
Nre = uD/

 = density = 1424.685 kg/m3

u = velocity = 1.667 rev/sec
D = diameter = 0.765 m
= viscosity = 0.006 kg/m.sec
Nre = 2.316467 * 105
Using table between power and Reynolds number
Npr = 2.4
P = Npr n3 D5
= 4150 watt
= 5.56 h.p
= 6 h.p.

3). Storage Tank:

Mass of acid in tank = 1000 ton = 1000,000 kg

Density of acid = 1332 kg/m3
Volume of acid in tank = 750 m3
Take 10% overflow margin,
So,
Total Volume = 750 m3 * 1.1
= 825 m3
Geometry of Tank:
Diameter of tank = D
Height of tank = H = D
V = /4D2H
D = 11 m
H = 11 m
Thickness of Shell:
Pi = gH
= 1332 * 9.8 * 11
= 143589.6 N/m2
Thickness of Shell = ts
=PiDi/2Jf Pi + C
Pi = design pressure
Di = inside diameter of tank
C = corrosion allowance = 2mm

J = efficiency factor = 0.8

F = stress value = 85 N/m.m2
Ts = 14 mm
4). PUMP:
Mass flow rate = 290 ton/day
= 12083.33 kg/hr
Density = 1198 kg/m3
= 0.006 kg/m.sec
Volume flow rate = 10.086 m3/hr
Z=6m
L = 50 m
= 75%
Le/D = 32 (90 degree elbow)
No. of elbows = 4
No. of Valve = 1
Le/D = 300 for globe valve
Le/D = 7 for open gate valve
No. of valves = 1
Nre = uD/
q = uA
u = q/A

= 1.08 m/sec
So,
Nre = 831497.22
From friction factor chart,
f = 0.0059
Total Le for fittings, valves = 22.31 m
f = friction for pipes, fittings
= 2fV2 (L + Le) / gc D
= 33.l25 J/Kg
Wo = 39.143
Wo = 97.86 J/Kg
= 1490 J/Sec
Wo = 2 h.p
BHP = Q * H * /3960*