Professional Documents
Culture Documents
Magnus Evertsson
Objectives
Effect of Wear
Plant performance
Part replacement
Time
Effect of Wear
Plant performance
You can
experience
strange variations
then sampling.
Time
Effect of Wear
Take home message:
Frequency
Lower Limit
Plant performance
Upper Limit
Effect of Wear
Small wear tolerance
+ High average performance
- High replacements costs
- Frequent stops
Optimization of a Tertiary
Crushing Stage
Background
Some limestone quarries in the Mid West produce
excessive amounts of fines <4# (<4.7mm)
A typical modern crusher produces 19-21%
A typical old crusher produces 14-15%
Modern crushers have high power input/draw which
is achieved by large throws,
BUT these machines produce more fines.
Optimization of a Tertiary
Crushing Stage
Optimization of a Tertiary
Crushing Stage
H3800 Hydrocone
Standard MC and
modified
chambers
Eccentric speed
360->288 rpm
Throw
36->29 mm
Breakage Modes
Interparticle
CHOKE LEVEL
Less confinement
-mixed single and
interparticle breakage
Single particle
Chamber Design
Test Procedure
Careful calibration
50 tests
CSS=minimum, , 14, 15, 16, ...,21 mm
0.063
0.125
0.25
0.5
1
2
4
5.6
8
11.2
16
22.4
25
31.5
26
3.4
6.3
9.9
13.5
18.1
26.1
38.3
46
62.6
81.1
96.4
100
100
100
27
3
5.6
9.1
12.3
16.2
23
33.3
42.2
55.8
71.7
92.9
100
100
100
28
3.1
5.4
7.9
10.3
13.4
19
28.2
32
48.5
65.3
92.6
100
100
100
29
2
3.9
6.3
8.5
11.2
16.1
23.9
31.1
41.8
57.2
80.1
99.1
100
100
30
2.4
4.2
6.3
8.3
10.9
15.7
23.8
30.5
41.3
56.6
83.2
97.7
100
100
31
1.8
3.6
5.9
8
10.5
14.8
21.5
27.7
36.9
52
76.5
97.3
100
100
33
1.6
3.1
4.8
6.4
8.5
12.3
18.4
23.6
31.7
41.9
62.3
93.6
94.9
100
34
3.3
6.3
10.1
13.8
18.5
26.5
38.5
45
60.1
74.7
93.5
100
100
100
35
2.6
4.9
7.7
10.5
14.1
20.8
31
39.8
52.4
68.6
87.8
98.5
100
100
36
2.3
4.5
7.1
9.5
12.7
18.2
27
32.6
45.4
60.6
86.7
100
100
100
37
2.1
4.1
6.5
8.8
11.8
17.2
25.2
32.3
43.1
56.3
79.2
100
100
100
38
2.2
4.3
6.9
9.3
12.2
17.1
24.6
31.6
40.9
53.8
77
96.8
100
100
39
2
4.1
6.8
9.2
11.9
16.1
22.3
26
36.1
48.6
69.3
92.6
95.6
100
41
1.5
2.9
4.6
6.3
8.5
12.4
18.7
24
32.9
45.2
65.8
93.6
100
100
42
3
5.4
8.2
11.2
15.4
22.5
32.8
41.3
53.2
68.5
90
100
100
100
43
2.5
4.5
7.1
9.9
13.5
19.5
27.8
35.7
45
59.7
81.1
97.5
100
100
44
2.3
4.2
6.7
9.1
12.3
18.1
26.3
31.2
43.8
57.7
77.1
95.1
98.1
100
45
2.3
4.5
7.1
9.7
13
18.5
26.4
32.5
41.9
53.4
71.8
95.4
97.5
100
46
1.9
3.6
5.6
7.6
10.2
14.5
20.5
26.9
33.2
42.1
58.5
87.8
94.4
100
47
1.7
3.2
4.9
6.7
9.1
13.3
19.1
23.2
31.7
40
54.4
86.8
93.9
100
49
1.3
2.7
4.2
5.8
8.1
12.1
18.1
22
30.3
39.5
55.4
84.4
93.4
100
50
1.5
3.1
4.9
6.6
8.4
11.9
17.5
21.5
29
38.4
54.1
81.2
92.2
100
Standard
80
Modified
70
60
Is there a difference?
50
40
30
20
Feed
10
0
0.1
10
Particle size [mm]
100
Total Capacity
[tph]
160
STD
140
120
Modified
Q [tph]
100
80
60
40
29/288
20
36/360
0
12
13
14
15
16
17
18
CSS [mm]
19
20
21
22
23
24
Product Yield
0-2, 2-16 and +16mm, [%]
80
60
Yield [%]
50
Modified
40
STD
20
13
14
15
16
17
18
CSS [mm]
19
20
21
22
23
24
90
STD
29/288
36/360
80
70
Modified
Q [tph]
60
50
40
30
20
10
0
12
13
14
15
16
17
18
CSS [mm]
19
20
21
22
23
24
STD
Modified
3
0
12
13
14
15
16
17
18
CSS [mm]
19
20
21
22
23
24
Economical Analysis
Gross profit
= potential sales production costs
Economical Analysis
Costs
[USD]
Feed material
Crushing cost
Step
1
2
3
4
5
6
1.30 1.40 1.50 1.60 1.70 1.80
0.34 0.37 0.40 0.42 0.45 0.47
Income
[USD]
Typical product
Handling of fines
Economical Analysis
CSS
P
p
Q
[mm]
[kw]
[Mpa ]
[tph]
29/288
29/288
36/360
12.5
14
15
16
17
18
19
20
133 111 105
89
92
87
79
74
5.6 4.6 4.0 3.2 3.4 3.0 2.8 2.6
95
97 101 105 109 109 103 114
15.8
17
18
19
20 21 22 23
148 123 126 101 100 91 84 80
4.6 4.2 3.8 2.7 2.7 2.5 2.2 2.3
120 125 130 137 126 134 134 138
36/360
Yield [%]
0-2
2-16
+16
Volumes [tph]
0-2
2-16
+16
25
67
3
22
68
7
19
74
7
17
67
21
17
74
18
16
67
26
13
53
37
14
57
43
27
81
12
24
77
24
24
77
30
25
73
39
18
55
52
18
55
61
16
58
60
16
58
63
Economical Analysis
29/288
36/360
Economics
29/288
Step 1
Cost per ton $/ton
Gross profit $/ton
Gross profit $/hour
Step 2
Cost per ton $/ton
Gross profit $/ton
Gross profit $/hour
Step 3
Cost per ton $/ton
Gross profit $/ton
Gross profit $/hour
Step 4
Cost per ton $/ton
Gross profit $/ton
Gross profit $/hour
Step 5
Cost per ton $/ton
Gross profit $/ton
Gross profit $/hour
Step 6
Cost per ton $/ton
Gross profit $/ton
Gross profit $/hour
36/360
2,15
29/288
2,10
36/360
2,05
2,00
1,95
3,10
12 13 14 15 16 17 18 19 20 21 22 23 24
CSS [m m ]
3,05
Cost [$/ton]
Cost [$/ton]
2,20
3,00
29/288
2,95
36/360
2,90
2,85
2,80
2,75
12 13 14 15 16 17 18 19 20 21 22 23 24
CSS [m m ]
Cost [$/ton]
1,20
1,00
0,80
29/288
0,60
36/360
0,40
0,20
0,00
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
CSS [m m ]
Profit [$/hour]
120
100
80
29/288
60
36/360
40
20
0
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
CSS [m m ]
Yield
0-2, 2-16 and +16mm, [%]
80
65%
55%
70
60
2-16 m m , std
Yield [%]
50
40
+16 m m , std
30
20
0-2 m m , std
10
13
14
15
16
17
18
19
CSS [m m ]
15%
18%
20
21
22
23
24
Standard
80
Modified
70
60
Is there a difference?
50
40
30
20
Feed
10
0
0.1
10
Particle size [mm]
100
Conclusions
Optimization of a Crushing Stage
Difficult to observe the differences from PSD graphs
Careful analyses of yield required
Maximize yield
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