Calc Face SheetReference Prcedure EN-P-008Calculation Face SheetLevel 1: Full Verification (Complex Permanent Works Design)Project:CORe FEL3 StudyProject No.:H335456Level 2: Spot Verification (Simple Permanent Design)Client:ValeNo. of Sheets:6Level 3: Spot Verification (Complex Temporary Works Design)Discipline:MechanicalRevision:ALevel 4: No Verification (Simple Temporary Works Design)Calc. Title:Blower Sizing CalculationCalc. Doc. No.:PreliminaryLevel 5: Review by Lead Engineer (Preliminary Design)Description:Blower duty calculations for new Rougher/Scavenger and Pyrrhotite Rougher /Scavenger floatation cellsCategory of calculation verification required:Level 5: Review by Lead Engineer (Preliminary Design)Prepared by:Date: Aug 03, 2009Print Name:B. PerryPreliminary review by:Date:Print Name:Can the calculation now be released for work?NoTo the Client?NoChecked by:Date:Print Name:Reviewed by:Date:Print Name:Approved by:Date:Print Name:General Notes:REVISIONSRevisionDatePreparedCheckedApprovedDescriptionSuperseded by Calculation No.:Date:Reason voided:

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Blower Sizing CalcCALCULATION SHEETSHEET NO.__1__OF__6__DESCRIPTIONPROJECT NO.MADE BYCHECKED BYCORe Feasibility Study - Blower SizingH335456B. PerryDATEJul 27. 10DATEAssumptions:1. Blower air will be distributed to the floatation plant via a single header with branches to each bank of cellsRougher/scavengers:5x Outotec XHD-1002. Nominal pipe sizing based on nominal air velocity of 65 ft/sAir required per cell:25Am3/min3. Pipe sizes based on ANSI B36.10 std wt pipe (final pipe spec will most likely use thinner wall)Pressure required at top of cell:38kPa(g)4. Pipe absolute roughness coefficient for medium-smooth pipe:e =0.0003ft5. Atmosphere assumed as standard air (64 oF, 14.7 psi):Density,r =0.0753lbm/ft3Pyrrhotite rougher/scavengers:5x Outotec XHD-100Air required per cell:25Am3/min6. Effect of moisture in air is negligible, Gas constant for dry air:Pressure required at top of cell:38kPa(g)7. Compressibiliy effects on system losses is negligible8. Temperature effects on system losses is negligible9. Friction losses and dynamic losses in fittings are factored based on a design factor, df =1.5Floatation Cell Requirements:Rougher/scavengers:10x Outotec XHD-100Air required per cell:883Aft3/minPressure required at top of cell:5.51psigPyrrhotite rougher/scavengers:10x Outotec XHD-100Air required per cell:883Aft3/minPressure required at top of cell:5.51psigAssuming an ideal gasp = rRTpstd / rstd.Tstd = p1 / r1.T1 = RAssuming T1 = Tstd,forp1 =5.51psigr1 =0.1035318648lbm/ft3For conservation of mass:rstd.Qstd = r1.Q1Standard air required per cell:Qstd =1213.9std ft3/minTotal standard air requirement:=24277.5119485342std ft3/min(20cells)CALCULATION SHEETSHEET NO.__2__OF__6__DESCRIPTIONPROJECT NO.MADE BYCHECKED BYCORe Feasibility Study - Blower SizingH335456B. PerryDATEJul 27. 10DATEMain Air Header Size:Total flow, for20cells:Q =20x883=17657.3333607443Aft3/min =294.2888893457Aft3/sIdeal pipe area for 65 ft/s velocity:Ap = Q / 65 =4.5ft2Ideal pipe internal diamater,Di = ( 4 * Ap / p ) 1/2 =2.40ft=28.81inClosest standard pipe size is 30 inch OD, Std wt wall thickness = 0.375 inch, Di =29.25inSingle Bank Air Header Size:Flow:Q = 5 x 883 =4414Aft3/min =73.6Aft3/sIdeal pipe area for 65 ft/s velocity:Ap = Q / 65 =1.1ft2Ideal pipe internal diamater,Di = ( 4 * Ap / p ) 1/2 =1.20ft=14.41inClosest standard pipe size is 16 inch OD, Std wt wall thickness = 0.375 inch, Di =15.25inSingle Cell Air Pipe Size:Flow:Q = 1 x 883 =883Aft3/min =14.7Aft3/sIdeal pipe area for 65 ft/s velocity:Ap = Q / 65 =0.2ft2Ideal pipe internal diamater,Di = ( 4 * Ap / p ) 1/2 =0.48ft=5.81inClosest standard pipe size is 6 inch OD, Std wt wall thickness = 0.280 inch, Di =5.44inAssumed Configuration:CALCULATION SHEETSHEET NO.__3__OF__6__DESCRIPTIONPROJECT NO.MADE BYCHECKED BYCORe Feasibility Study - Blower SizingH335456B. PerryDATEJul 27. 10DATEApproximate System Losses:Formulae:ref. ASHRAE Handbook 2009 ed.Blower to Header:Nominal pipe size = 18"Pipe internal diameter = hydraulic diameter:Dh =17.25inPipe Area:Ap = p * (Dh / 2) 2Ap =233.7in2=1.62ft2Flow:Q =4414Aft3/minVelocity:V = Q / ApV =2720Aft/minApproximate Pipe Length:L =20ftApproximate Reynolds number:Re =3.99E+05Friction factor:0.01390.0139299581Friction pressure loss:Dpf =0.123inch WG=0.0044519126psiEstimated total losses:0.185inch WG=0.0066778689psiHeader:Nominal pipe size = 30"Pipe internal diameter = hydraulic diameter:Dh =29.25inPipe Area:Ap = p * (Dh / 2) 2Ap =672.0in2=4.67ft2Flow:Q =17657Aft3/minVelocity:V = Q / ApV =3784Aft/minApproximate Pipe Length:L =50ftApproximate Reynolds number:Re =9.41E+05Friction factor:0.01200.011989157Friction pressure loss:Dpf =0.303inch WG=0.0109335602psiEstimated total losses:Dpf . df =0.454inch WG=0.0164003403psiCALCULATION SHEETSHEET NO.__4__OF__6__DESCRIPTIONPROJECT NO.MADE BYCHECKED BYCORe Feasibility Study - Blower SizingH335456B. PerryDATEJul 27. 10DATEHeader To Last Cell:Nominal pipe size = 16"Pipe internal diameter = hydraulic diameter:Dh =15.25inPipe Area:Ap = p * (Dh / 2) 2Ap =182.7in2=1.27ft2Flow:Q =4414Aft3/minVelocity:V = Q / ApV =3480Aft/minApproximate Pipe Length:L =141ftApproximate Reynolds number:Re =4.51E+05Friction factor:0.01370.0136698407Friction pressure loss:Dpf =1.580inch WG=0.0570355545psiEstimated total losses:Dpf . df =2.371inch WG=0.0855533318psiCell Feed Line:Nominal pipe size = 6"Pipe internal diameter = hydraulic diameter:Dh =5.44inPipe Area:Ap = p * (Dh / 2) 2Ap =23.2in2=0.16ft2Flow:Q =883Aft3/minVelocity:V = Q / ApV =5470Aft/minApproximate Pipe Length:L =15ftApproximate Reynolds number:Re =2.53E+05Friction factor:0.01540.0154439848Friction pressure loss:Dpf =1.315inch WG=0.0474710063psiEstimated total losses:Dpf . df =1.973inch WG=0.0712065095psiSummation of System Losses =4.98inch WG =0.18psiBlower Discharge PressureEstimated blower discharge pressure:= pressure required at cell + system losses=5.51+0.18=5.69psig=157.7inch WGCALCULATION SHEETSHEET NO.__5__OF__6__DESCRIPTIONPROJECT NO.MADE BYCHECKED BYCORe Feasibility Study - Blower SizingH335456B. PerryDATEJul 27. 10DATEBlower PowerBlower power,HP = Q.Dp / 6356.hfDp in inch WGAssuming total fan efficiency, hf =0.7Estimated from curveTotal blower power,HPtotal =860HPFor four duty blowers, power for each,HPea =215.1HPRecommend 250 HP drive motor.Spencer Power Mizer Blower Size SelectionTotal blower capacity, Qtotal =24277.5119485342std ft3/minFor four duty blowers, Qea =6069.3779871336std ft3/minApproximate blower total pressure, pt =157.7inch WG=5.7psigCALCULATION SHEETSHEET NO.__6__OF__6__DESCRIPTIONPROJECT NO.MADE BYCHECKED BYCORe Feasibility Study - Blower SizingH335456B. PerryDATEJul 27. 10DATESpencer Power Mizer Series 6000 Blower Recommended

105'20'16'30''18''6''16''16''