Simulation and advanced control of transient behaviour in gyratory cone crushers

Pekka Itvuo*, Antti Jaatinen**, Matti Vilkko*

*Tampere University of Technology, Finland **Metso Automation, Finland

Agenda
Introduction Dynamic model of a gyratory cone crusher Simulation results Conclusions

Introduction
Gyratory cone crushers are commonly used comminution equipment in mines and quarries
Gyratory cone crusher in this work refers to the secondary and tertiary hydrocone type crushes

Disturbances like changes in feed material size & hardness and wear of crushing liners cause variation in the crusher output
As a result, the process is never in a steady state although modelling is often carried out as if it were Desired performance is only achieved if the effect of occurring disturbances is fully compensated

Crushers are typically operated with constant closed side setting (CSS) or constant load None of the currently existing cone crusher models is truly useful for analytic control system design purposes
Modelling in crushers is biased towards process dimensioning and equipment design i.e. steady-state models

Introduction
Main components of a gyratory cone crusher
Closed side setting CVs have nonlinear & dynamic relationship with associated MVs & DVs

Operating variables of a gyratory cone crusher

Eccentric speed

Nominal stroke length

Dynamic model of a gyratory cone crusher

Modelling principle
Combine the existing static nonlinear performance models with simple linear dynamics Hammerstein type system:

Dynamic model of a gyratory cone crusher

w
Feed material + Material properties Moisture (M) Feed grading (FG) Crushability (LA) Feed rate (Q) Specific Gravity (SG) Feed flakiness index (FFI) Linear dynamics

64 63.5 CA 63 62.5 15 20 25 250 300 CSS 350 ES

400

450

Feed hopper model

Linear dynamics

Static nonlinearities (ANFIS)

Material volume in hopper [m3] Static nonlinearities (Log-transformed Linear regression) Product Size [mm]

Product size distribution model

CSS

Piston dynamics model Engine dynamics model

Flow model

Crusher dynamics model

Power model

RMS Power [kW]

ES

Stroke Linear dynamics

Cavity geometry Linear dynamics

Capacity model

Capacity [t/h]

Crusher constants

y = f (u (t ), w(t ))

Simulation results
-Controllability of product size distribution Metso Nordberg GP200M tertiary gyratory cone crusher
25 mm stroke length ~150 t/h capacity
Disturbance variable Specific Gravity Crushability, LA-value Feed moisture [%] Feed Flakiness Index Feed Grading [mm] Feed Rate [% of max] Min 2.6 17 0.1 10 5/32 75% Max 2.8 20 3.0 34 5/104 100%

Maximum effect of disturbances

Feed material, Granite

Variations based on realistic data on quarry operation

Maximum effect of manipulated variables

Influence of MVs exceed the maximum range of generated disturbances

Manipulated variable Closed side setting (CSS) Eccentric speed (ES)

Min 10 250

Max 30 450

Simulation results
-Product size distribution controlM o istu re [% ], F e e de q u iva le n t size / 1 0 [m m ] Moisture [%], Feed size/10 [mm] 3 P ro d u ct E q u iva le n tS ize [m m ] Product size [mm]

Metso Nordberg GP200M tertiary gyratory cone crusher

25 mm stroke length ~150 t/h capacity

DV: Change in feed size & moisture

Input Sequence 4 Moisture Feed size 3.5 15 14.5 14 13.5 13 12.5 12 11.5 11 10.5 10

CV: Product Size

Metso GP200 Product size Constant CSS Constant Size

Feed size 24 17 36 24

2.5

1.5

Feed material, Granite

LA 18.5, SG 2.7 [t/m]

Moisture 0.5 3 0.1 0.5 3

0.5

Nonlinear CSS actuator

Pump up On/off valve down

100

200 time [s]

300

400

500

100

200 time [s]

300

400

500

MV: Closed side setting (CSS)

Metso GP200 CSS 23 Constant CSS Constant Size 22 C ru sh e rP o w e rD ra w[kW ] [kW] Crusher Power 110 120 C lo se dS id eS e ttin g [m m ] Closed side setting [mm]

Crusher Power
Metso GP200 Power Draw Constant CSS Constant Size

Control objective:
Maintain the desired product size

21

100

20

19

90

Controller:
PID with Ziegler Nichols tuning

18

80

17

70 16

large CSS changes needed for steady product size

15 0 100 200 time [s] 300 400 500 60 0

constant power constant product size

100 200 time [s] 300 400 500

Conclusions
Current operating modes (constant CSS or constant load) cannot provide steady product size The effect of every reasonable process disturbance can be cancelled by using advanced feedback control system Further investigation and full-scale tests are needed in order to validate these findings