optimizing the crunch process · flakiness index css [mm] crusher performance map, ... test plan...
TRANSCRIPT
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Optimizing the "Crunch" process Per Svedensten
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� Methods to combine and simulate technical and economic performance
� Optimum crushing plant performance is difficult to achieve due the process characteristics. Different compared to all other industrial processes.
� Optimizing method for best performance
� Partly implemented in PlantDesigner 10
Optimizing the Process
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Value adding chain
Drilling Blasting Loading and Hauling Primary Crushing Crushing and Screening
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� Crushing stage� Crushing plant� Quarry process
� Today:� Optimizing a crusher� Optimize the feed� Optimize the process
Point of interestCrushing Plant Optimization
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� Cone Crusher Optimization� Case Study: Optimal Blasting for Crushing Plant Performance� Crushing Plant Design� Case Study: Optimizing a Crushing and Screening Process
Agenda
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� The crushers are the last size reduction stage in the value chain.
� Over crushing is common.
� The connection between crusher setting and yield is often unknown
� The rock cannot be repaired.
� We need to control the crusher carefully.
Optimization of a Final Crushing Stage
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� Optimization of one parameter (CSS) can be done by sampling and analysis
� The invested time and lost production will quickly be repaid by increased productivity
� Combine product yield and economic aspects
� This can be done by taking samples and making the analysis in MS Excel
Optimization of a Final Crushing Stage Planning Sampling Analysis Optimization
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� Material from crusher is sampled
� Measure the capacity at each crusher settings. CSS will effect the final product capacity, especially in a closed circuit.
� Production of 4 valuable products•2-4 mm
•4-8 mm•8-16 mm
•16-22 mm
� By-product with no value•0-2 mm
Run the crusher at different settings
Optimization of a Final Crushing StagePlanning Sampling Analysis Optimization
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Planning Sampling Analysis Optimization
� Run the crusher at different settings
� Take at least one sample at each setting. (Multiple samples are often useful)
� Special Attention to Safety when taking samples!!
� Position of point were samples are taking.
� Ensure that the conveyor will not start by accident.
Optimization of a Final Crushing Stage
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Planning Sampling Analysis Optimization
� Particle Size Distribution Plots
� If taking single samples on each CSS the risk of getting inconsistent results might make the graph look strange.
� Impossible to determine optimum setting by only using particle size distribution graphs
Optimization of a Final Crushing Stage
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Pa
ssin
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%]
Sieve Size [mm]
Particle Size Distribution at different CSS
13 mm
14 mm
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Planning Sampling Analysis Optimization
� Impossible to determine optimum setting by only using particle size distribution graphs
Optimization of a Final Crushing Stage
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CSS [mm]
Crusher Capasity
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sieve size [mm]
Particle Size Distribution
20…
� Combine the particle size distribution and capacity.
� Percentage of final product times the capacity gives the production capacity of each product.
� Example 2-4 mm at CSS 20mm:• Percentage of crusher production: 20% - 11% = 9%
• Crusher capacity 193 tph
• Total Production: 193 tph x 9% = 17 tph
Optimization of a Final Crushing StagePlanning Sampling Analysis Optimization
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Crusher Capasity
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Planning Sampling Analysis Optimization
� Entering all the values into MS Excel makes this easy to get production capacities.
� Still difficult to determine the optimal setting
Optimization of a Final Crushing Stage
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10 15 20 25
Pro
du
ct c
ap
aci
ty [
tph
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CSS [mm]
Crusher Production
0-2 mm
2-4 mm
4-8 mm
8-16 mm
16-22 mm
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Inco
me
[€]
CSS [mm]
Crusher Yield
0-2 mm
2-4 mm
4-8 mm
8-16 mm
� Use the price* per ton for all products:
•0-2 mm: € 0 (by-product)•2-4 mm: € 8.90•4-8 mm: € 10.00•8-16 mm: € 12.20•16-22 mm: € 7.80
� Make an income graph by combining prices with capacity
Optimization of a Final Crushing StagePlanning Sampling Analysis Optimization
*All prices are estimates based on publicly available data
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me
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CSS [mm]
Crusher Yield
0-2 mm
2-4 mm
4-8 mm
8-16 mm
� What difference does it make?
� Running the crusher 2 mm off:•Decrease the profit by 43€/h•Running the crusher at 1600 hours per year: 43*1600=68800 €
Optimization of a Final Crushing StagePlanning Sampling Analysis Optimization
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Inco
me
[€]
CSS [mm]
Crusher Yield
Income
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Crusher Performance MapPlanning Sampling Analysis Optimization
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Crusher Production
0-2 mm
2-4 mm
4-8 mm
8-16 mm
16-22
mm
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Crusher Performance Map from real dataCrusher Performance Map
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Pro
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CSS [mm]
Crusher Performance Map, CH430 F
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Pro
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CSS [mm]
Crusher Performance Map, CH430 F
0-2
2-5,6
5,6-8
8-11,2
11,2-16
16-22,4
2-11,2
5,6-16
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Crusher Performance Map from real dataCrusher Performance Map
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CSS [mm]
Crusher Performance Map, CH430
2-5
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6,3-8
8-10
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MinBaS IIOptimized blasting
� Field Study in Långåsen, Arlanda
� Aim: Evaluate the effect of using electronic blasting systems. Changes in particle size distribution and other benefits.
� Full scale testing. Four blasts blasted during 2008
� Based on the final report and my own observations
� All data and costs shown are estimates based on publically available data
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The Study
• Comparisons between the cost and earnings for different blasting strategies.
• Conclusions and recommendations
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The QuarryLångåsen, Arlanda
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![Page 23: Optimizing the Crunch process · Flakiness Index CSS [mm] Crusher Performance Map, ... Test plan Blast 1 Nonel Nonel ... Cost analysis Blasting result Nonel norm. q [€/ton]](https://reader031.vdocuments.us/reader031/viewer/2022022606/5b7e70c07f8b9a10598dc402/html5/thumbnails/23.jpg)
Blasted Material Test plan
Blast 1 Nonel Nonel
0.8 kg/m3 1.1 kg/m3
Blast 2 Nonel Nonel
1.1 kg/m3 0.8 kg/m3
Blast 3 Electronic Blasting System
0.8 kg/m3 10 ms between holes
Blast 4 Electronic Blasting System
0.8 kg/m3 5 ms between holes
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Measuring the Particle Size DistributionBlasting result
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Cost analysisBlasting result
Nonel norm. q
[€/ton]
Nonel high q
[€/ton]
EPD norm. q
[€/ton]
Drilling and Blasting
0.67 0.92 0.72
Added cost for detonators
0.00 0,00 0.22
Bolder Management
0.22 0.16 0.11
Sum [€/ton] 0.89 1.08 1.05
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� Loading and Hauling to primarycrusher
•Wheel loader carries the material from the muck pile tothe crusher
� Conducted studies
•Measurment of wheel loadedloading times
•Measurment of loaded material [tph]
•Manual timing during severaldays
Conditions and MeasurmentsLoading and Hauling
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Cost analysisLoading and Hauling
Nonel norm. q Nonel high q EPD norm. q
Contractor [€/h] 333 333 333
Loading Capasity [tph] 298 316 313
Cost [€/ton] 1.12 1.05 1.06
Sum incl Drilling and Blasting [€/ton]
0.89+1.12=
=2.011.08+1.05=
=2.131.05+1.06=
=2.11
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Plant Setup and Conditions for the StudyCrushing and Screening
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Performed MeasurementsCrushing and Screening
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Cost analysisCrushing and Screening
Nonel norm. q Nonel high q EPD norm. qPower Draw (kWh/ton) 0.3 0.25 0.35
Energy Cost (0.22 €/kWh) 0.07 0.06 0.08
Fixed Cost [€/h]
[€/ton]555
1.80
555
1.70
555
1.70
Cost [€/ton] 1.87 1.76 1.78
Sum incl D&B ochL&H [€/ton]
0.89+1.12+1.87=
=3.881.08+1.05+1.76=
=3.891.05+1.06+1.78=
=3.89
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Total cost $/hQuarry Production
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Nonel norm. q
Nonel high q
EPD norm. q
Production rate [tph] 298 316 313
Cost [€/h] 1343 1412 1425
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Product PriceQuarry Production
Fraction [mm]
Price
[€/ton]
Crushing stage
Ave. Price
[€/ton]
0-90 8.89 1 (Prim.) 8.89
0-4 14.33
3-4 15.78
4-8 15.44
8-11 17.67
11-16 16.78
16-32 15
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Revenue €/hQuarry Production
Nonel norm. q
Nonel high q
EPD norm. q
Production rate [tph] 298 316 313
Cost [€/h] 1343 1412 1425
Revenue [€/h] 3421 3567 3637
“Profit” [€/h] 2078 2155 2212Difference Nonelnorm q
[€/h]
[€/ton]
-
-
77
0.24
134
0.43
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� From the tested blasting alternative Electronic Blasting System is the most beneficial.
� Extensive investigations and analysis are necessary in order to determine the optimal solution. Many areas are effected by the blasting result.
•Drilling and Blasting•Bolder Management•Loading and Hauling•Crushing and Screening
� Only studying the costs is not sufficient in order to optimize the process. Most expensive solution did also generate the most profit.
Conclusions
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� Questions?
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� Optimizing a single crusher can be done manually as seen earlier
� Optimizing several crushers?•Combination of equipment setting
•Production situation, what products are demanded and what are not?
What about Optimizing the Crushing and Screening Process?
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Infrastructure for optimizationProcesses
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� Putting Crusher and Screens together to form processes•Screening duties•Open and Closed Circuits•Benefits and disadvantages with different circuit configurations.•Special Circuits•Combining Circuits to form plants
Processes
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The different screening tasksProcesses
Scalping
Natural Fines Removal Closed
Circuit Screening
Final Product Screening
Process Screening
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The different screening tasksProcesses
ProcessProduct
Process
From a process point of view Process and Product Screens are the most interesting
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� The material will not pass the crusher more then once
� Limited size of crushers and screens
� Material will have improved quality
� Top size control
� Primary and Secondary Applications
Open CircuitProcesses
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� All or parts of the material will pass the crusher at least one time.
� Screens placed in order to return over size material to crusher.
� Top size control.
Closed Circuit
Processes
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� Pre crusher screening
•Finished material removed before crusher
•Consider the quality of the by passed material
Closed CircuitProcesses
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� Post Crusher Screening•Large crusher needed•Will improve the product quality•More material in the crusher generates more wear
•Closed side setting will have a great effect on the circulating load, might effect overall circuit capacity
Closed CircuitProcesses
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� When designing crushing plats a combination of different crushing circuits are needed.
� Combining Crushing Stages to optimum performance is very difficult.
� Saving in one stage might cost more in the next.
� Simulation program is needed.
Open and Closed Circuits
Processes
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Post ProductScreen
Double ProductScreens
No ProductScreen
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+ Limited size of crushers and screens+ Material will have improved quality- No Top size control
+ Smaller sized crusher can be used-/+ Some quality improvment in all material+ Top size control
+ Material will have improved quality
- Bigger sized crusher is needed
+ Top size control
- Only one product +Improved quality in all material
- Cost for screens- By-pass material will not improve in quality
Note: Quality is defined as strenght and average shape
- By-pass material will not improve in quality
Selecting and Combing Circuits Processes
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+ Limited size of crushers and screens+ Material will have improved quality- No Top size control
+ Smaller sized crusher can be used-/+ Some quality improvment in all material+ Top size control
+ Material will have improved quality
- Bigger sized crusher is needed
+ Top size control
- Only one product +Improved quality in all material
- Cost for screens- By-pass material will not improve in quality
Note: Quality is defined as strenght and average shape
- By-pass material will not improve in quality
Selecting and Combing Circuits Processes
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+ Limited size of crushers and screens+ Material will have improved quality- No Top size control
+ Smaller sized crusher can be used-/+ Some quality improvment in all material+ Top size control
+ Material will have improved quality
- Bigger sized crusher is needed
+ Top size control
- Only one product +Improved quality in all material
- Cost for screens- By-pass material will not improve in quality
Note: Quality is defined as strenght and average shape
- By-pass material will not improve in quality
Selecting and Combing Circuits Processes
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Special CircuitsProcesses
� Selection screen•Combining two crusher in one stage.•Increases flexibility and makes process adjustment easier.
� Parallel Crushers•Flexibility in capacity•Run at different settings to get a wide curve•Better shaped material in a wide part of the product.
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Screening Stages
Processes
Final screening in order to make several productsConsider possibilities for re-crushing products
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� Equipment performance is the starting point for process performance.•Selecting the right equipment for the right task
� Processes and plants can be configured in many ways•Understanding the pros and cons of processes and how to combine processes is important.
� Different types of circuits•Open/Closed•Product Screen / Process Screen•Screening before / after crusher
Summary and ConclusionsProcesses
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� To optimize the crushing plant using computer optimization
� Use sampling to calibrate the computer model in order to increase model accuracy
� Optimize with the goal to maximize gross profit
Objective of projectCrushing plant optimization using TCO
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Crushing plant model
Simulation
Optimisation
Economy
Yield the most profitable production strategy and meet the market demand
Modelling
Production units Rock material Customer demands
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� A method to estimate the life cycle cost of equipment.
� NOT for deciding to invest!
� One method to calculate and compare cost for products or processes
� Purpose•Mean production cost per ton•Compare and evaluate different equipment solutions•Crushing Plant Optimization•Total analysis of quarry operation, combine with other processes
Total Cost of Ownership
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� Some costs are more visual then others
� Often other costs and performance figures will have a bigger impact on the ownership cost and earnings. Investment cost is just the top of the iceberg.
� TCO will bring light on the entire Iceberg, not just the normally visible top.
Relations between costsTotal Cost of Ownership
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� Includes equipment performance
� Divided into: Ownership and operating costs.•Ownership typically fixed costs•Operating cost typically variable
� Even more powerful when used on systems of equipment.•Crushing and Screening Plant•Load and haul systems
� Considers Availability and Utilization
Total Cost of Ownership
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� Aimed at the crushing and screening process
� Vehicles needed for plant operation is in the boarder area for the calculation
� Most difficult to handle is how the plant is operated.
•Maintenance policy –Repairs
Area of interestIncluded in the TCO calculation
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� It is important to establish the correct level of details when estimating costs
� To detailed: •Enormous amount of work•The extra work will give little benefit•Small changes or uncertainties will ruin the work
� Not detailed enough:•Changes in production will not affect the costs. Optimization and other analysis are not possible.
Area of interestIncluded in the TCO calculation
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Product Profit Analysis
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Product
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Net Sales Price
Average Production Cost
The Difference between getting it right and wrongCost Calculation
Product Profit Analysis
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Product
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Net Sales Price
Real Production Cost
Average Production Cost
Using Average CostThe production cost is summed up and divided equally
Using “real” production cost
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� Included in cost the calculation•Raw material•Depreciation •Interest •Energy cost•Wear parts replacement•Service cost•By-product production•Personnel
TCO and Gross Profit
� Income calculation•Sellable products•Product demand
� Other factors included that effects the gross profit
•Availability•Utilization
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� Some parts are difficult
� Strategy: Do your best, make estimations and guesses, and you will be close to the actual cost!
Does in look difficult?TCO and Gross Profit
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Plant ChallengesCrushing plant optimization using TCO
Capacity
By-product Highly desired
What is the best trade-off between capacity and reduction?
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In normal production following CSS are utilized:Secondary crusher CSS 44 mmTertiary crusher CSS 16 mmQuaternary crusher CSS 13 mm
Products:0-2 mm2-5 mm5-8 mm8-11 mm11-16 mm16-22 mm
Test plantCrushing plant optimization using TCO
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Objectives for the first test session:
� Measure particle size distribution to calibrate the model
� CSS at original settings
Test planCrushing plant optimization using TCO
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Model CalibrationCrushing plant optimization using TCO
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The computer tool automatically finds the best solution using an optimization algorithmThe solution that yields the best profit:
� Secondary crusher CSS 50 mm (44)� Tertiary crusher CSS 20 mm (16) � Quaternary crusher CSS 14 mm (13)
Running the TCO optimization moduleCrushing plant optimization using TCO
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Crushing plant optimization using TCO
Increased Capacity
Reduced fines ratio Increased total production
Result: +11 % in Calculated Gross Profit
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� Optimization must be a combination of technical and economic analysis
� Computer optimization can improve productivity
� Model calibration increases accuracy
� Minimizing cost does not necessarily maximize profit
� Combined performance of different machines should be considered. Solves the trade-off between capacity and reduction
Crushing plant optimization using TCO
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