Calibration and Validation of a Cone Crusher Model with Industrial Data

Duarte, Robson A.; Yamashita, André S.; Silva, Moisés T. da; Cota, Luciano Perdig�ão; Euzébio, Thiago A. M.

doi:10.3390/min11111256

Cited by 9 publications

(7 citation statements)

References 33 publications

(57 reference statements)

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“…where εi is the compression ratio in the i-th crushing zone. Based on the improved model of inter-particle breakage considering the transformation of the particle shape for the cone crusher [27][28][29], the crushing process of particles in the crushing chamber was simulated by measuring the feed bulk properties of the cone crusher and calculating the compression ratio of each crushing zone in the crushing chamber. Based on the particle crushing pressure model, the particle crushing pressure distribution of the mantle and concave can be obtained according to the compression ratio and particle size distribution coefficient of each crushing zone in the crushing chamber, as shown in Figure 6.…”

Section: Particle Crushing Pressure Distribution In the Crushing Chambermentioning

confidence: 99%

Constant Wear Criterion for Optimization of the Crushing Chamber of Cone Crushers

2022

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The crushing chamber is the core component of a cone crusher, consisting of mantle and concave parts. Reducing the impact of crushing chamber wear on the performance of cone crushers and the quality of crushed products while extending the service life of the mantle and concave has become a significant research challenge. The impact of the compression ratio and particle size distribution coefficient on the particle crushing pressure is investigated here in order to establish the particle pressure model. The effect of the normal and tangential components of particle crushing pressure on the wear of the mantle and concave is discussed, and the wear with the increase in crushed products and accumulation of operating time is explored in order to develop a wear model of the crushing chamber. By evaluating the compensation of the worn crushing chamber according to the adjustment mechanism of the mantle, a constant wear criterion for the crushing chamber of the cone crusher is proposed. Through analysis of industrial experimental data on an experimental prototype of a ZS200MF cone crusher with an optimized mantle and concave, the capacity was found to fluctuate at 83.45 t/h with no apparent downward trend, the calibration size production was reduced by 6.2%, and the wear similarity coefficient was 8.82%. This indicates that replacing the optimized mantle and concave based on the constant wear criterion maintains the performance of the cone crusher, delays the decline in the quality of the crushed products, and ensures similarity between the adjusted worn crushing chamber and the initial crushing chamber, which verifies the feasibility and effectiveness of the constant wear criterion for the optimization of crushing chamber. Based on the constant wear criterion, cone crushers can be optimized to obtain a crushing chamber with constant wear characteristics, which provides theoretical support for the development of new high-efficiency cone crushers as well as the optimization of existing equipment.

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Section: Particle Crushing Pressure Distribution In the Crushing Chambermentioning

confidence: 99%

Constant Wear Criterion for Optimization of the Crushing Chamber of Cone Crushers

2022

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“…In this stage, the ROM is commonly directed to feeders whose function is to guarantee mass flow to the primary crusher. Then, the crushed mass goes to a circuit of conveyor belts that lead this material to the secondary crushing stage [ 2 , 3 ]. Feeders are used to control the flow of ore to the belt conveyor circuits.…”

Section: Introductionmentioning

confidence: 99%

Delay Compensation in a Feeder–Conveyor System Using the Smith Predictor: A Case Study in an Iron Ore Processing Plant

Moraes,

da Silva,

Euzébio

2024

Sensors

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Conveyor belts serve as the primary mode of ore transportation in mineral processing plants. Feeders, comprised of shorter conveyors, regulate the material flow from silos to longer conveyor belts by adjusting their velocity. This velocity manipulation is facilitated by automatic controllers that gauge the material weight on the conveyor using scales. However, due to positioning constraints of these scales, a notable delay ensues between measurement and the adjustment of the feeder speed. This dead time poses a significant challenge in control design, aiming to prevent oscillations in material levels on the conveyor belt. This paper contributes in two key areas: firstly, through a simulation-based comparison of various control techniques addressing this issue across diverse scenarios; secondly, by implementing the Smith predictor solution in an operational plant and contrasting its performance with that of a single PID controller. Evaluation spans both the transient flow rate during step change setpoints and a month-long assessment. The experimental results reveal a notable increase in production by 355 t/h and a substantial reduction in flow rate oscillations on the conveyor belt, evidenced by a 55% decrease in the standard deviation.

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“…In [25], the working process of hammer crushers was optimized using the method of DEM discrete elements. The authors of [26,27] conducted important studies on the calibration and verification of the cone crusher model. They formulated the calibration problem as an optimization problem based on the least square method.…”

Section: Introductionmentioning

confidence: 99%

“…The results of works [20][21][22][23][24][25][26][27][28] are extremely important, and the authors achieved good results. Nevertheless, they cannot be directly used to model and optimize the parameters of a single-roll gyratory crusher.…”

Section: Introductionmentioning

confidence: 99%

Mathematical Modeling and Multi-Criteria Optimization of Design Parameters for the Gyratory Crusher

et al. 2023

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There are a sufficient number of works devoted to modeling crushing machines. Nevertheless, the fact that there are a large number of working conditions, and the ongoing development of science and technology, require continuous improvement and specification of the models intended for crushing processes and those of the devices concerned. However, there are few studies related to single-roll gyratory crushers. Such crushers are promising for use in mines to crush rocks laid in the developed space. Mathematical modeling and optimization of the design parameters of the working chamber and the executive body (roll) of a single-roll gyratory shaft crusher, designed for crushing strong rocks, was performed in this paper. A differential equation was derived. As a result of its solution, the rational shape of the working chamber cheek of the single-roll gyratory crusher was established, representing a logarithmic spiral arc. Analytical expressions were derived to determine the rational rotation speed and productivity of the crusher under consideration. Expressions for calculating the kinematic load components acting on the roll were formulated. They are the periodic functions of the shaft rotation angle. The Fourier series expansion showed that the loads contained harmonics of the first, second, third and fourth orders. Using the concept of fuzzy sets, a multi-criteria optimization of the design parameters of the working chamber was performed, including the values of the eccentricity and the central angle of the beginning of the cheek profile. The variation coefficients of the kinematic components of the loads acting on the working body reduced, due to the optimal choice of the working chamber profile and the angular coordinates of the installation of the fixed cheeks. The torque reduced 1.67 times, while the radial load decreased 1.2 times.

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Calibration and Validation of a Cone Crusher Model with Industrial Data

Cited by 9 publications

References 33 publications

Constant Wear Criterion for Optimization of the Crushing Chamber of Cone Crushers

Constant Wear Criterion for Optimization of the Crushing Chamber of Cone Crushers

Delay Compensation in a Feeder–Conveyor System Using the Smith Predictor: A Case Study in an Iron Ore Processing Plant

Mathematical Modeling and Multi-Criteria Optimization of Design Parameters for the Gyratory Crusher

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