Real-time Optimization of a speed controlled Cone Crusher in an Iron Ore application

Paper in proceeding, 2014

Cone crushers are often used as an intermediate comminution step in the mining industry. Real-time feedback data on the product streams can be obtained by applying mass-flow sensors to the process. With a frequency converter also the eccentric speed in a cone crusher can be adjusted in real-time in addition to the CSS. The adjustment of these two online parameters in real time results in an increased potential for production yield; however, a nontrivial optimization problem with a large solution space also arises. As the feed material also varies, and the wear is highly evident, the optimal setting for the parameters varies in time. In this paper a secondary cone crusher in an iron ore application is equipped for real-time optimization with both mass flow meters, connection to plant SCADA, a CSS control system and a frequency converter. The objective is to optimize the feed to the downstream mills in real-time. The guiding tests indicated a more beneficial operating point, where higher power consumption could be achieved in the crusher without increasing the pressure as much. There are operating points which are more beneficial than others, and it is not the nominal one (factory setting) that is the best. In this paper the result from a survey together with a fully automated real-time algorithm is presented. The results from a full sampling survey tell that the production of particles smaller than 1 mm can be increased with 17.5%. A fully automated algorithm is currently being tested.