2019

Hydro-cyclone Separation Unit

Cost Estimations
Technical Report
12/9/2019
 Table of Contents
1. Primary Crusher ...................................................................................................................... 3

2. SAG Mill (Primary Grinder) ................................................................................................... 3

3. Ball mill (Secondary Grinder) ................................................................................................ 4

4. Froth Flotation Machines ........................................................................................................ 4

5. Hydrocyclone .......................................................................................................................... 5

5.1. Input Data ......................................................................................................................... 5

5.2. Calculations ...................................................................................................................... 6

5.2.1. Size of one Cyclone .................................................................................................. 6

5.3. Cost Estimation ................................................................................................................ 8

6. Trommel Screen ...................................................................................................................... 8

6.1. Technical Specifications .................................................................................................. 9

6.2. Requirements .................................................................................................................... 9

6.3. Cost Estimation: ............................................................................................................... 9

6.3.1. Nearest available Specifications in market ............................................................. 10

7. Vibration Screen ................................................................................................................... 10

7.1. Reuirements .................................................................................................................... 10

7.2. Cost Estimation .............................................................................................................. 10

7.2.1. Nearest available Specifications in market ............................................................. 11

8. Slurry Charge Pump .............................................................................................................. 12

 8.1. Input Data ....................................................................................................................... 12

8.2. Calculations .................................................................................................................... 13

8.3. Cost Estimation .............................................................................................................. 13

8.3.1. Pump Motor ............................................................................................................ 13

8.3.2. High Pressure Horizontal Centrifugal Sand Suction Slurry Gravel Pump ............. 14

9. Belt Conveyer with hopper ................................................................................................... 15

9.1. Requirements .................................................................................................................. 15

9.2. Cost Estimation .............................................................................................................. 15

9.2.1. Specifications .......................................................................................................... 16

10. Thickener ........................................................................................................................... 16

11. Mineral Sorting Machine ................................................................................................... 17

12. Labor Cost (Variable) ........................................................................................................ 17

13. Maintenance Cost (Variable) ............................................................................................. 17

14. Conclusion ......................................................................................................................... 18

15. References .......................................................................................................................... 19

 1. PRIMARY CRUSHER

Required capacity = 500 tons/day = 21 t/h

Available product = 30 kW (15-50 t/h)

Cost = $2400

Reference: https://www.alibaba.com/product-detail/PE-400-600-laboratory-mobile-
mini_62030486538.html?spm=a2700.7724838.2017115.36.f0f354b63XbtTn&s=p

2. SAG MILL (PRIMARY GRINDER)

Cost: $4500

Reference: https://www.alibaba.com/product-detail/Mining-machinery-ore-sag-mill-
in_60528753201.html?spm=a2700.7724838.2017115.255.490639a9uaMQi8

3. BALL MILL (SECONDARY GRINDER)

Capacity = 21 tons/h

Cost = $15000

Reference: https://www.alibaba.com/product-detail/Energy-saving-diesel-engine-dry-
type_60817146387.html?spm=a2700.7724838.2017115.15.ab585783vcWUFQ&s=p

4. FROTH FLOTATION MACHINES

Capacity = 19.08 m3/h = 0.33 m3/min for three units (0.11 m3/min for one unit)
Cost: $10000/Unit = $30000 (3 Units)

Reference: https://www.alibaba.com/product-detail/High-efficiency-copper-ore-froth-
flotation_1653880763.html?spm=a2700.7724838.2017115.260.5a115851dk9G1i

5. HYDROCYCLONE

5.1. Input Data

Capacity = 500 ton/day

Number of cyclones = 8
 4 × (Total Solid in tons per hour)
Flow rate in U. S GPM = Qm =
Cw

kg
Weight of dry solids 241
day
Where, Cw = = = 4.82 × 10−4
Total weight of Ore kg
500000
day

0.2409 ton
4 ×( ) m3 m3
Qm = 24 hr = 83.33 Gallons Per Minute = 0.0053 = 19.08
4.82 × 10−4 s h

All cyclones shall be connected in parallel so that if one cyclone gets damaged then other cyclones
must be working side by side.

Flow rate Qtotal 0.0053

= = = 0.0006625 m3 /s
cyclone 8 8

5.2. Calculations

All cyclones shall be connected in parallel so that if one cyclone gets damaged then other cyclones
must be working side by side.

5.2.1. Size of one Cyclone

Qm 83.33 GPM
Flow rate for single cyclone = = = 10.42 GPM
8 8
 m3
Qm 19.08 hr
Flow rate for single cyclone = = = 2.385 m3 /hr
8 8

Using a single cyclone chamber inlet pipe diameter Di = 2 inch = 0.0508 m, we can have inlet
velocity of cyclone as

Q πD2i π × (0.0508)2
Inlet Velocity = vi = , where a = = = 0.00203 m2
a 4 4

𝑄 0.0006625
vi = = = 0.326 m/s
a 0.00203

8Q 8 × 0.0006625
Chamber Diameter = Dc = √ = √ = 0.128 m
vi 0.326
 𝐂𝐲𝐜𝐥𝐨𝐧𝐞 𝐂𝐡𝐚𝐦𝐛𝐞𝐫 𝐃𝐢𝐚𝐦𝐞𝐭𝐞𝐫 = 𝐃𝐜 = 𝟏𝟐𝟖 𝐦𝐦

Dc 128
Diameter of overflow Outlet = Do = = = 32 mm
4 4

Using above graph, we get

Diameter of underflow pipe or Spigot = Du = 0.7 × 25.4 = 17.78 𝑚𝑚

5.3. Cost Estimation

Minimum Cost = $3000/Unit

Reference:

https://www.alibaba.com/product-detail/Gravity-Processing-dewatering-hydrocyclone-Water-
Cyclone_60670547294.html?spm=a2700.7724838.2017115.37.719d1638RMChM4&s=p

6. TROMMEL SCREEN

The trommel screen is completed using the material self-weight while rotating. The three coupling
shafts are designed higher than the screening surface, which enables the larger particles being
stirred up and thus increases the screening efficiency. The particles larger than screen mesh size
are discharged as the upper size materials which could be delivered away by belt conveyor, while
the particles smaller than screen mesh are discharged as undersize materials which could be fed
into the following equipment.

Reference: https://hengchengmachinery.com/products/trommel-screen/?portfolioCats=12
 6.1. Technical Specifications

500 t
Required Capacity = = 20.833
24 h

Using standard table from the given reference:

6.2. Requirements

By doing interpolation from the data available, we got

Required Product Capacity Power Drum Diameter Drum Length

Trommel Screen 20.83 t/h 3 kW 947 mm 1208 mm

6.3. Cost Estimation:

Reference: https://www.alibaba.com/product-detail/Hot-sale-sand-gold-ore-
washer_60642576511.html?spm=a2700.7724838.2017115.172.254d59c02FPEp0
Desired product can be ordered by providing our required details as calculated before.

6.3.1. Nearest available Specifications in market

Drum
Requirements Capacity Power Drum Length Cost
Diameter

Rotating drum
50 t/h 4 kW 1000 mm 1500 mm $2900
trommel screen

7. VIBRATION SCREEN

7.1. Reuirements

Capacity = 20.83 ton/h

Layers = 3

7.2. Cost Estimation

Reference: https://www.alibaba.com/product-detail/Factory-gravel-screen-machine-3-
layer_60795703324.html?spm=a2700.7724838.2017115.13.2a63660dRdI6Z8&s=p
 7.2.1. Nearest available Specifications in market

Spec of
Requirements Capacity Power Layers Cost
screen

3 layer 1200 X 3700

7.5-80 t/h 7.5 kW 3 $1000
vibrating screen mm
8. SLURRY CHARGE PUMP

8.1. Input Data

m3 m3
Qm = 83.33 Gallons Per Minute = 0.0053 = 19.08
s h

Maximum Velocity at pump discharge = vd = 8 × (Velocity at cyclone inlet)

vd = 8 × 0.326 = 2.608 m/s

Required Pump Discharge pressure = pd = Maximum Pressure at cyclone inlet

pd = 3.5 bar
Using maximum number of solids to solution ratio (1:0.68) with maximum specific gravity of dry
solids i.e. 5, we get

Specific gravity of pulp = ρ = 2.27

kg
Maximum Density of pulp = 2.27 × 1000 = 2270
m3

8.2. Calculations

First assuming discharge head,

Maximum Discharge Head = H = 125 m

Allowable head should be less than 125 m according to the pump available in market

Using

m kg m3
Pump Output Power = Po = ρgQH = 9.81 2 × 2270 3 × 0.0053 × 125 m
s m s

𝐏𝐨 = 𝟏𝟒𝟖𝟒𝟐 𝐖 = 𝟏𝟒. 𝟖𝟒 𝐤𝐖 = 𝟐𝟎 𝐡𝐩

Considering Motor/Diesel generator as 80% efficient,

𝐏𝐨 𝟏𝟒. 𝟖𝟒
𝐏𝐦 = = = 𝟏𝟖. 𝟓𝟓 𝐤𝐖 = 𝟐𝟓 𝐡𝐩
𝟎. 𝟖 𝟎. 𝟖

8.3. Cost Estimation

8.3.1. Pump Motor

Selected Motor: HUIHENG MEP 180M-4 (1465 RPMs)

Maximum Cost per unit = $850

https://www.alibaba.com/product-detail/400-600V-18-5kW-AC-
Three_60109978399.html?spm=a2700.7724838.2017115.258.698d7db69LHDDd
Specifications

Name: 400/600V 18.5kW AC Three Phase IE3 Electric Motor

8.3.2. High Pressure Horizontal Centrifugal Sand Suction Slurry Gravel Pump

Cost: $1812/Unit

Reference: https://www.alibaba.com/product-detail/Mud-pumps-ex-price-12x10-
high_62164850427.html?spm=a2700.7724838.2017115.187.7cd9bc85Owg2Zg
Specifications:

9. BELT CONVEYER WITH HOPPER

9.1. Requirements

Capacity = 5-300 ton/h (Can be ordered according to the requirements)

Power = 1.5 – 30 kW (Can be ordered according to the requirements)

9.2. Cost Estimation

Minimum Cost = $1200/Unit

Reference: https://www.alibaba.com/product-detail/Used-grain-unloading-flat-belt-
conveyor_60621967274.html?spm=a2700.7724838.2017115.1.666d142e0RknFn
 9.2.1. Specifications

10. THICKENER

Cost = $12000 (Capacity = 560 tons/day)

Reference: https://www.alibaba.com/product-detail/High-efficiency-Mining-Thickener-For-
Gold_62017778518.html?spm=a2700.7724838.2017115.194.416d4196sYjfPT
 11. MINERAL SORTING MACHINE

Cumulative minerals weight = 240 kg/day

Cost: $2000

Reference: https://www.alibaba.com/product-detail/conveyor-and-sorter-automatic-weigher-
and_60840098937.html?spm=a2700.details.deiletai6.9.2c4861f2AkQbrg

12. LABOR COST (VARIABLE)

It takes minimum one year to construct a plant. Minimum wage of labor in USA is $7.25 per hour
in 2019.

Reference: https://smallbiztrends.com/2019/01/minimum-wage-2019.html

𝐋𝐚𝐛𝐨𝐫 𝐂𝐨𝐬𝐭 = 𝐂𝐨𝐬𝐭 𝐩𝐞𝐫 𝐡𝐨𝐮𝐫 × (𝟑𝟔𝟓 − 𝐇𝐨𝐥𝐢𝐝𝐚𝐲𝐬 𝐩𝐞𝐫 𝐲𝐞𝐚𝐫) × (𝐰𝐨𝐫𝐤𝐢𝐧𝐠 𝐡𝐨𝐮𝐫𝐬)

𝐋𝐚𝐛𝐨𝐫 𝐂𝐨𝐬𝐭 = $𝟐𝟓 × (𝟑𝟔𝟓 − 𝟗𝟔) × (𝟖) = $𝟓𝟑𝟖𝟎𝟎

13. MAINTENANCE COST (VARIABLE)

It is the cost usually used to maintain good health of a unit. According to cost analyzers,
maintenance cost must be less than 3% of the Estimated Replacement Value i.e. estimated
installation cost.
Reference: https://www.idcon.com/resource-library/articles/lean-maintenance/1072-
maintenance-cost-and-estimated-replacement-value.html

Hence,

𝐌𝐚𝐱𝐢𝐦𝐮𝐦 𝐦𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐂𝐨𝐬𝐭 = 𝟎. 𝟎𝟑 × $𝟏𝟏𝟓𝟎𝟐𝟒 = $𝟑𝟒𝟓𝟎. 𝟕𝟐/𝐥𝐢𝐟𝐞𝐭𝐢𝐦𝐞

14. CONCLUSION

References have also been added along each section for the ease of access. Cost provided in this
report are estimated on the bases of different manufacturer’s costs. Some manufacturer’s give
different costs for each of their model. In those cases, specified models shall be considered.
15. REFERENCES

1. https://www.alibaba.com/product-detail/Gravity-Processing-dewatering-hydrocyclone-
Water
Cyclone_60670547294.html?spm=a2700.7724838.2017115.37.719d1638RMChM4&s=p
2. https://hengchengmachinery.com/products/trommel-screen/?portfolioCats=12
3. https://www.alibaba.com/product-detail/Hot-sale-sand-gold-ore-
washer_60642576511.html?spm=a2700.7724838.2017115.172.254d59c02FPEp0
4. https://www.alibaba.com/product-detail/Factory-gravel-screen-machine-3-
layer_60795703324.html?spm=a2700.7724838.2017115.13.2a63660dRdI6Z8&s=p
5. https://www.alibaba.com/product-detail/400-600V-18-5kW-AC-
Three_60109978399.html?spm=a2700.7724838.2017115.258.698d7db69LHDDd
6. https://www.alibaba.com/product-detail/Mud-pumps-ex-price-12x10-
high_62164850427.html?spm=a2700.7724838.2017115.187.7cd9bc85Owg2Zg
7. https://www.alibaba.com/product-detail/glass-bolted-coated-steel-water-
tank_60523174172.html?spm=a2700.wholesale.deiletai6.4.612d2853hE4Wcs
8. https://www.alibaba.com/product-detail/Used-grain-unloading-flat-belt-
conveyor_60621967274.html?spm=a2700.7724838.2017115.1.666d142e0RknFn
9. https://smallbiztrends.com/2019/01/minimum-wage-2019.html
10. https://www.idcon.com/resource-library/articles/lean-maintenance/1072-maintenance-
cost-and-estimated-replacement-value.html