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tremendous amount
of material is crushed
each year by cone
crushers, but despite
this a detailed knowledge of how
cone crushers work from a
process point of view is quite
poor.This paper presents a model
for predicting cone crusher
performance.The model can be
used as a simulation tool to assist
in the design of crushers, allowing
any arbitrary design of cone
crusher to be studied. If a set of
simulations is performed for a
given crusher, a ‘crusher
performance map’ can be created
which can then be used when
optimizing a given crushing task
or crushing plant.
Sandvik Rock Processing are
currently using this performance
model to predict the gradings
from a new design of ‘fine
chamber’ crushers.This will allow
the company to offer and supply
Performance
by Design
crushers which are designed to
meet the specific demands of fine
crushed-product applications with
a high level of confidence.
Rock
fragmentation
characteristics
To quantify the S and B functions
laboratory-scale compression
crushing tests were performed6.
(1)
In the tests the rock material was Equation (1)
crushed in a steel cylinder, the
equipment being designed to
imitate the conditions under
which a volume of material is
compressed in a real crushing
Fig. 5. a) Two-variable
chamber2,3.
selection function fitted
The value of selection is to experimental data
obtained directly from the b) In 3D the function
compression tests.The achieved
values of S are plotted in figure
appears as a surface
in space
5a against the compression ratio
which is denoted s⊄. It is clear
that the breakage probability S
varies both with the compression
ratio and with the feed size
distribution.The particle size
distribution is characterized by its
width or spread and is assumed
to be reflected by a normalized
standard deviation σ⊄ of the figure 6. similar breakage behaviour,
distribution.The value of S It is obvious that the overall although, for a given compression
increases with increasing s⊄, reduction increases when the s⊄ ratio, gneiss generates more fines
ratio increases. A function given in than diabase.
equation (2) with s⊄ as a
which is an obvious and natural
behaviour.The size distribution
width influences the value of S, so parameter and four constants can Flow model
be fitted to the experimental The crushing process is modelled
data3,6. Here x⊄ is a particle size
that for short fractions higher
values of the breakage probability as a series of repeated crushing
relative to the initial particle size events.The flow model must
x0.The particle size x⊄ is defined
are obtained compared to wide
therefore predict where, and
in equation (3), in which xmin is a
fractions.
The two-variable selection under which conditions (how),
function S(s⊄, σ⊄) in equation (1) small reference particle size. the material is compressed during
can satisfactorily describe the For comparison, data for each size-reduction cycle. For a
diabase are also shown in figure given rock material, the operators
Si and Bi depend on the utilized
breakage probability6.The
63. It can be seen that the two
compression ratio ® (s/b)u.The
appearance of the selection
function achieved after fitting different types of rock have a
equation (1) to experimental data
Fig. 6. a) Normalized
is shown in figure 5.The good fit
breakage behaviour of
with the experiments confirms the tested gneiss
the assumption about the material6
behaviour of the selection b) Comparison of the
function. breakage behaviour for
The breakage behaviour is diabase3 and gneiss6
described with a breakage
function B.The breakage function
is a cumulative function and the
value of B describes the relative
amount (by mass) of particles
passing a given relative size. For a
given original particle size, the
(2)
breakage behaviour is assumed
only to be dependent on the
compression ratio. Normalized
(3)
size distributions resulting from
the compression tests with
different s⊄ ratios are shown in Equations (2) and (3)