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SME Arizona Conference 2004 Quarry Academy 2005 Cone Crusher Cone Crusher Modelling Modelling Magnus Evertsson Applied Mechanics Chalmers University of Technology Göteborg, Sweden

Cone Crusher Modelling - Metallurgist & Mineral … · Cone Crusher Modelling ... ¾Utilization of compressive size reduction in cone crushers ¾Energy efficient crushing ¾Robust

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Page 1: Cone Crusher Modelling - Metallurgist & Mineral … · Cone Crusher Modelling ... ¾Utilization of compressive size reduction in cone crushers ¾Energy efficient crushing ¾Robust

SME Arizona Conference 2004Quarry Academy 2005

Cone Crusher Cone Crusher ModellingModelling

Magnus EvertssonApplied Mechanics

Chalmers University of TechnologyGöteborg, Sweden

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Quarry Academy 2005

Background

Aggregate producers on the Swedish west-coast required

more knowledge aboutcrushing…

Modelling of cone crushers startedin December 1993.

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Quarry Academy 2005

Cone Crushers

Cone Crushers=

Size Reduction

Mechanical mineral liberation - miningAggregate production - quarries

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Quarry Academy 2005

Cone CrushersCrushing plant - Mining

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Quarry Academy 2005

Cone CrushersCrushing plant - Aggregate

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Quarry Academy 2005

History

1954 Fred Bond’s WI1954 Gauldie1970 Bill Whiten1991 Ted Bearman

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Quarry Academy 2005

Objectives

FundamentalsPrediction of particle size distributionPrediction of crushing pressure distributionsPrediction of crushing forcesPrediction of power draw

Design considerationsUtilization of compressive size reduction in cone crushersEnergy efficient crushingRobust performance over total liner lifetime

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Quarry Academy 2005

Product

Feed

Power

Cross-section of a cone crusher

Operating Principle

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Quarry Academy 2005

Operating Principle

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Quarry Academy 2005

Operating Principle

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Quarry Academy 2005

Operating Principle

XFlow

XTemperature

Up/downL/R

Dependencies for a water tap...

Diagonal interdependency matrix – system is easy to control

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Quarry Academy 2005

Operating Principle

Dependencies for a cone crusher...

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Quarry Academy 2005

Crusher Model

Rock Material

CrusherDynamicsCrusher

Design Performance

Pressure

WearSizeReduction

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Quarry Academy 2005

Crusher Model

The crushing process can be described with two functions.

Selection S – which?Breakage B – how?

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Quarry Academy 2005

Crusher Model

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Quarry Academy 2005

Rock Breakage Behavior

F

F

b

s

Form conditionedcompression-displacement controlled

( ),F F s σℵ ℵ=

ssbsize distribution widthσ

=

=

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Quarry Academy 2005

Rock Breakage Behaviour

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Quarry Academy 2005

Rock Breakage Behaviour

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Quarry Academy 2005

Rock Breakage Behavior

( ) 2 2 2 2 21 2 3 4 5 6,p s a s a s a s a s a s a s

size distribution width

σ σ σ σ σ

σℵ ℵ ℵ ℵ ℵ ℵ ℵ ℵ ℵ ℵ ℵ ℵ

= + + + + +

=

Multi (inter) particle-pressure response

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Quarry Academy 2005

Rock Breakage Behavior

( ) ( )321 2, kF s d d k s k s

s compression ratiod particle size

ℵ ℵ ℵ

= +

==

0 0.05 0.1 0.15 0.2 0.25 0.3 0.350

500

1000

1500

2000

2500

3000

3500

4000

quartzite 16-19o tests- simulations

Single particle-force response

s/b

F [N]

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Quarry Academy 2005

Crushing Pressure and Power Draw

OSS CSS

iR( )p p α=

Concave

Mantle( )( )

sintan

cosi

p d

p d

α α αα

α α α= ∫∫

( ) sin

sinii

p r dR

α α α

α= ∫

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Quarry Academy 2005

Crushing Pressure and Power Draw

2 2 11 2

cos sincos( )

resres e

e

a eP Rh

ω ϕ αϕ ϕ

=+

Mechanical model of

spiderless cone crusher

SYMONS-type

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Quarry Academy 2005

Crushing Pressure and Power Draw

Mechanical model of a top supported

cone crusher

HYDROCONE-type

1 22 2 1

1 2 1

sin sin cos sincos( ) cos

resw res e

e

a eP h Rh

ϕ ϕω ϕ α

ϕ ϕ ϕ⎛ ⎞

= −⎜ ⎟+⎝ ⎠

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Quarry Academy 2005

Geometry

StdSH

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Quarry Academy 2005

Geometry

Design drawings

FineCoarse

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Quarry Academy 2005

Geometry

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Quarry Academy 2005

Flow model

Material flow mechanics

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Quarry Academy 2005

Flow model

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Quarry Academy 2005

Flow model

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Quarry Academy 2005

Interaction Flow-Size reduction

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Interaction Flow-Size reduction

Less confinement-mixed single and interparticle breakage

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Quarry Academy 2005

Results

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Quarry Academy 2005

Results - Particle size distributions

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Quarry Academy 2005

Results - Particle size distributions

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Quarry Academy 2005

Results - Particle size distributions

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Quarry Academy 2005

Results - Compression ratio

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Quarry Academy 2005

Results - Pressure

-only a small proportion of the crushing chamber is utilized

H3000-FCSS=10mmGneiss10-30mm

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Quarry Academy 2005

Results - Crushing force

0 2 4 6 8 10 120

5

10

15

20

25

30

35

40

Crushing zone [No]

Cru

shin

g fo

rce

[kN

]

ID3F36010, H3000F, n=360, CSS=10.1, e0=15.2, td=0.01, #IP=2.5169

Total vertical force

188.3 kN

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Quarry Academy 2005

Results - Crushing angle

0 2 4 6 8 10 1210

15

20

25

Crushing zone [No]

α [°

]

ID3F36010, H3000F, n=360, CSS=10.1, e0=15.2, td=0.01, #IP=2.5169

-very small crushing angles

[ ]α °

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Quarry Academy 2005

Results - Crushing power

0 2 4 6 8 10 120

1

2

3

4

5

6

7

8

Crushing zone [No]

Pow

er [k

W]

ID3F36010, H3000F, n=360, CSS=10.1, e0=15.2, td=0.01, #IP=2.5169

Total power

47.5 kW

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Quarry Academy 2005

Results

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Quarry Academy 2005

Results

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Quarry Academy 2005

Results

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Quarry Academy 2005

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Quarry Academy 2005

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Quarry Academy 2005

H7800-Implementation of Results

Anglo American

Mantos Blancos

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Quarry Academy 2005

H7800-Implementation of Results

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Quarry Academy 2005

H7800-Implementation of Results

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Quarry Academy 2005

3C-Implementation of Results

3C-teamCustomizedCrushingChambers

Fine Tuned Chambers