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Journal ArticleDOI

Modelling and simulation of dynamic crushing plant behavior with MATLAB/Simulink

01 Apr 2013-Minerals Engineering (Pergamon)-Vol. 43, pp 112-120
TL;DR: In this article, a novel approach for simulating dynamic plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink is presented, where an example of an existing crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator.
About: This article is published in Minerals Engineering.The article was published on 2013-04-01. It has received 28 citations till now. The article focuses on the topics: Process control.
Citations
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Journal ArticleDOI
TL;DR: In this paper, the hazards posed by heavy metals effluents on the environment and use of various Streptomyces species to remove heavy metals from aqueous solution are discussed.
Abstract: Heavy metals, derived from industrial wastewater discharge, present a serious threat to human health and to natural water. Biosorption is regarded as a cost-effective biotechnology for the treatment of high volume and low concentration wastewaters containing heavy metal(s) in the order of 1 to 100 mg L−1. Among the biomaterials for heavy metal removal which have been researched during the past decades is the Streptomyces species, a by-product of an industrial antibiotic fermentation process. This paper describes the hazards posed by heavy metals effluents on the environment and use of various Streptomyces species to remove heavy metals from aqueous solution. Characterization of Streptomyces species, factors affecting biosorption, biosorption isotherms and biosorption kinetics is discussed.

36 citations

Journal ArticleDOI
TL;DR: The purpose of the roadmap is to conceptualize the methodology, position relevant previous work along this methodology and identify further research challenges to develop the industrial applicability of the methodology.

17 citations

Journal ArticleDOI
TL;DR: Two 2D three-degrees-of-freedom dynamic models for a vibrating screen are tested, using linear and nonlinear approaches for angular displacement, and it is concluded that the linear dynamic model used in Case 2 is adequate to evaluate the influence of the ore on the movement of the vibratingScreen.
Abstract: Vibrating screens are critical machines used for size classification in mineral processing. Their proper operation, including accurate vibration movement and slope angle, can provide the benefits of energy savings and cost reductions in the screening process and the whole mining process. Dynamic models of the vibrating screen movement available in the literature do not simulate ore motion or its interaction with screen decks. The discrete element method (DEM) allows for the calculation of the dynamic of the ore. In this paper, two 2D three-degrees-of-freedom dynamic models for a vibrating screen are tested, using linear and nonlinear approaches for angular displacement. These models consider the inertia of the ore and the ore force calculated with DEM. A double-deck linear motion vibrating screen is simulated using the DEM software LIGGGTHS. DEM is used to obtain the ore parameters in the steady state and the force on the screen decks. Two cases are compared: Case 1 considers the ore as moving together with the vibrating screen, and Case 2 considers the ore force on the screen deck as calculated by DEM. Simulations are carried out with data for an industrial vibrating screen used in copper mining. The force over the screen is significantly different between the cases. Case 1 produces a force that is unrealistic because the ore cannot produce a high-amplitude adhesion force over the screen decks. In Case 2, no adhesion force acts between the ore and deck. It is concluded that the linear dynamic model used in Case 2 is adequate to evaluate the influence of the ore on the movement of the vibrating screen. The linear dynamic model considering the force as in Case 1 can be used to simulate a vibrating screen, as long as a correct calibration parameter is included to obtain an accurate motion amplitude.

14 citations

Journal ArticleDOI
TL;DR: In this article, a new wear prediction model is proposed combining the empirical model for predicting liner wear with time parameter, and a simple and practical model, based on the wear model and interparticle breakage, is presented for calculating compression ratio of each crushing zone along with liner wear.
Abstract: Cone crushers are used in the aggregates and mining industries to crush rock material. The pressure on cone crusher liners is the key factor that influences the hydraulic pressure, power draw and liner wear. In order to dynamically analyze and calculate cone crusher performance along with liner wear, a series of experiments are performed to obtain the crushed rock material samples from a crushing plant at different time intervals. In this study, piston die tests are carried out and a model relating compression coefficient, compression ratio and particle size distribution to a corresponding pressure is presented. On this basis, a new wear prediction model is proposed combining the empirical model for predicting liner wear with time parameter. A simple and practical model, based on the wear model and interparticle breakage, is presented for calculating compression ratio of each crushing zone along with liner wear. Furthermore, the size distribution of the product is calculated based on existing size reduction process model. A method of analysis of product size distribution and shape in the crushing process considering liner wear is proposed. Finally, the validity of the wear model is verified via testing. The result shows that there is a significant improvement of the prediction of cone crusher performance considering liner wear as compared to the previous model.

13 citations


Cites background from "Modelling and simulation of dynamic..."

  • ...This will affect the PSD curve and the flakiness index curve [4,5]....

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Journal ArticleDOI
TL;DR: In this paper, the authors proposed a system based on a radio frequency identification (RFID) tracer in a plastic shell to track ore transported between stockpiles and bins in a mine.
Abstract: recovery in the mineral processing circuit is affected by upstream operations. The upstream operations in a conventional copper mine include blasting, excavation, crushing, transportation, stockpile storage, as well as milling in semi-autogenous grinding (SAG) and ball mills. Varying the specific explosive energy may have a significant impact on the downstream comminution processes, and can maximize the cost savings between blasting and ball milling while achieving a sufficiently small P80 at the ball mill (Chung and Katsabanis, 2000; Nielson and Lownds, 1997; Nielsen and Malvik, 1999; Scott, 1996). P80 is the 80% passing size in the cumulative size distribution (both post-blast and post-mill fragmentation), and it is generally used as a representative size of the fragmentation in the hard-rock mining industry. However, for a mine with two or more ore types, these savings are difficult to estimate in absence of an ore-tracking method that can detect ore type as well as estimate fragment sizes (Kim and Kemeny, 2011). There are challenges to ore-tracking methods as well, resulting from thorough mixing of ore, for example at the stockpiles. Dissimilarities between ore types in terms of their blastability, crushability, and grindability add to the complexity of estimating the energy expenditure required to achieve a target P80 during milling. In summary, although it may be difficult, it is important for mine operators to distinguish between ore types so as to be able to calibrate the total explosives energy accordingly in order to maximize the total cost savings over a period of time. Tracking systems have been used in mines for other purposes in the past. A system based on a radio frequency identification (RFID) tracer in a plastic shell has been developed (Jansen et al., 2009). Although this tracer does not provide continuous tracking of all ore types in a mine, it could be used to track ore transported between stockpiles and bins. Similarly, RFID tracers have been used to track blast movements (La Rosa and Thornton, 2011). Continuous tracking already exists for all ore transported from pits to crushers (Modular Mining, 2014). This tracking is based on global positioning system (GPS) devices attached to the trucks hauling ore from shovel sites to the primary crushers. However, the tracking process does not continue through the comminution circuit and stockpiles. Thus, tracking ore movement from blast sites to the ball mills requires prediction and tagging of ore type of each individual fragment transported on trucks and conveyors. Tagging and prediction is useful in mines where the majority of fragments are over 1 inch A mine-to-mill economic analysis model and spectral imaging-based tracking system for a copper mine

12 citations


Cites methods from "Modelling and simulation of dynamic..."

  • ...There are several recent applications of process simulation to model the underlying dynamics in crushers (Asbjörnsson, Hulthén, and Evertsson, 2012, 2013; da Cunha, de Carvalho, and Tavares, 2013; Asbjörnsson et al., 2016)....

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References
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Book
01 Jan 1995
TL;DR: In this paper, the Proportional-Integral-Derivative (PID) algorithm is used to tune a PID controller for dynamic performance. But, it is not suitable for non-linear processes.
Abstract: 1 Introduction to Process Control 2 Control Objectives and Benefits 3 Mathematical Modeling Principles 4 Modeling and Analysis for Process Control 5 Dynamic Behavior of Typical Process Systems 6 Empirical Model Identification 7 The Feedback Loop 8 The Proportional-Integral-Derivative (PID) Algorithm 9 PID Controller Tuning for Dynamic Performance 10 Stability Analysis and Controller Tuning 11 Digital Implementation of Process Control 12 Practical Application of Feedback Control 13 Performance of Feedback Control Systems 14 Cascade Control 15 Feedforward Control 16 Adapting Single-Loop Control Systems for Non-Linear Processes 17 Inferential Control 18 Level and Inventory Control 19 Single-Variable Model Predictive Control 20 Multiloop ControlEffects of Interaction 21 Multiloop Control Performance Analysis 22 Variable Structure and Constraint Control 23 Centralized Multivariable Control 24 Process Control Design Definition and Decisions 25 Process Control Design Managing the Design Procedure 26 Control for Product Quality and Profit Appendices

453 citations


"Modelling and simulation of dynamic..." refers methods in this paper

  • ...Dynamic simulators have been used for years in control development and verification is many industries (Rajamani and Herbst, 1991; Marlin, 2000)....

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Dissertation
01 Jan 2000
TL;DR: In this paper, a method for prediction of cone crushers performance is presented, which is based on the laws of mechanics and constitutive relations concerning rock breakage characteristics, and can be used as a simulation tool to assist in the design process of a cone crusher.
Abstract: Cone crushers are used by both the aggregate producing and the mining industry. Both industries are interested in increasing the product quality while at the same time lowering the production costs. Prediction of crusher performance has been focused on, since crushing is a vital process for both industries. In the thesis a method for prediction of cone crusher performance is presented. The model is based on the laws of mechanics and constitutive relations concerning rock breakage characteristics. There are some crucial assumptions which are of central interest for the model. The validity of these assumptions has been verified by full-scale tests. The overall size reduction process is a result of several subsequent crushing events. Therefore, the process occurring in a cone crusher must also be modelled in the same repetitive way. Each crushing event is modelled with a selection and a breakage function. Selection corresponds to the probability of a particle being broken when an aggregate of particles is compressed. Breakage represents the way a single particle is broken into smaller fragments. The appearance of the selection and breakage functions is rock material specific and can be obtained by laboratory tests. The characterization of the fragmentation behaviour for rock materials is done by form conditioned compression crushing tests. Two modes of breakage are possible to achieve in a cone crusher. The location of the choke level is the criterion which determines the breakage mode. Interparticle breakage is achieved above the choke level while only single particle breakage is achieved below this level. The crusher model takes the fragmentation behaviour of the rock and feed size distribution into consideration. Moreover, chamber and machine geometry, together with machine parameters such as closed side setting, stroke and eccentric speed, is accounted for. On all occasions continuity of mass is preserved. Three main factors are identified to promote the size reduction process occurring in a cone crusher. These factors are: breakage modes, number of crushing zones, and compression ratio. The main factors are affected by both design and operating parameters. For a given crusher, the factors depend on eccentric speed, closed side setting, rock material breakage characteristics and feed size distribution. The main factors provide a fundamental and detailed understanding of how a cone crusher operates. Any design consideration should be evaluated against these main factors. The model can be used as a simulation tool to assist in the design process of crushers. Any arbitrary design can then be studied. If a set of simulations is performed for a given crusher, a Crusher Performance Map is achieved, which in turn can be used when optimizing a given crushing task or a crushing plant.

74 citations

Journal ArticleDOI
TL;DR: In this paper, the population balance model of the ball mill and an empirical model for the hydrocyclone were used for off-line tuning of a proportional integral (PI) controller.

51 citations


"Modelling and simulation of dynamic..." refers methods in this paper

  • ...Dynamic simulators have been used for years in control development and verification is many industries (Rajamani and Herbst, 1991; Marlin, 2000)....

    [...]

Dissertation
01 Jan 2010
TL;DR: In this article, real-time optimization is explored to the control of eccentric speed and on-line CSS adjustment based on information from the process, and the goal for the algorithms is to maximize the product yield in a given moment.
Abstract: Cone crushers are used in the mineral, mining, and aggregate industry for fragmentation and production of rock materials. Cone crusher control systems are widely used for machine protection, wear compensation and, to some extent, increasing production. These systems ordinarily focus on the crusher and not the yield of production process. In this thesis real-time optimization is explored to the control of eccentric speed and on-line CSS adjustment based on information from the process. The objective is to develop theories, models, software and hardware that enable real-time optimization of a single crushing and screening stage. The main hypothesis is that fixed parameters can never be optimal over time because many things in the process vary continuously. The eccentric speed in a cone crusher determines the number of times a material is compressed and thus the particle size distribution of the product. The speed of the crusher is usually fixed since speed change by changing pulleys is a labor intensive activity. By applying a frequency converter to the crusher motor power supply, it is possible to continuously adjust the eccentric speed. The cost for frequency converters has decreased significantly over the last decade. By applying mass-flow sensors to the process, e.g. conveyor-belt scales, the crusher result can be monitored and the result can be fed back to an operator or a computer. To analyze data from the process and automatically calculate the appropriate value for the Closed Side Setting (CSS) and eccentric speed, algorithms have been developed. The goal for the algorithms is to maximize the product yield in a given moment. The algorithms are loaded into computer systems that can communicate with sensors and crushers. The developed algorithms are tested and evolved at full-scale aggregate crushing plants. Crushing stage performance increased 3.5% in terms of production yield compared to a fixed CSS when the algorithm was implemented in addition to the existing control system. The algorithm automatically compensates for changes in the feed material and also decreases the need for calibration of the CSS. The crushing stages where the speed algorithm were tested increased their performance by between 4.2% and 6.9% compared to a good fixed speed. In real life however, the performance was increased by almost 20% since an inappropriate speed was selected during installation. As a bonus, on one of the test plants for the dynamic speed, the lifetime of the manganese wear parts increased 27% on the evaluated crusher, as a consequence of changed crusher dynamics. In conclusion, real-time optimization has been demonstrated to be feasible and increases the production yield with significantly numbers and should thus be of commercial interest to the industry.

39 citations


Additional excerpts

  • ...A closed loop process control for cone crusher as presented by Hulthén (2010). G....

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20 Nov 2013

37 citations