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Carl Magnus Evertsson - One of the best experts on this subject based on the ideXlab platform.

  • Two Variable Real-Time Algorithm for Cone Crusher Control
    2017
    Co-Authors: Erik Hulthén, Carl Magnus Evertsson
    Abstract:

    Cone crushers are used in the mineral, mining, and aggregate industry for fragmentation of rock materials. Control systems for cone crusher setting (CSS) are widely used to compensate for wear and to protect the crusher. With a frequency converter the eccentric speed in a cone crusher can be adjusted in real-time. The eccentric speed of the main shaft affects the number of compressions the material is exposed to and thus the capacity and the particle size distribution of the product. By applying mass-fl ow sensors to the process, a feedback of the different product yields is obtained in every moment. In this paper, a model and an algorithm are presented. The algorithm takes the incrementally increasing CSS into account and compensates for this with a successively changing eccentric speed. In order to implement the algorithm, a monitoring and control system is developed, including the online algorithm for selection eccentric speed. The different product fl ows from the Crushing Plant are continuously monitored by mass fl ow meters. The fi tness function is set by the Plant management depending on production targets and market situation. An earlier developed Finite State Machine (FSM) algorithm is also implemented and evaluated in the system. The developed algorithm has been validated and verifi ed at a Crushing Plant for aggregates with a production of around 400 kton a year. The new algorithm is shown to increase the Crushing stage throughput with 6.9 per cent. The FSM algorithm, on the other hand, increases the throughput with 5.3 per cent, which is a confi rmation of the magnitude of its benefi ts demonstrated in an earlier paper.

  • An On-line Training Simulator Built on Dynamic Simulations of Crushing Plants
    IFAC Proceedings Volumes, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Carl Magnus Evertsson
    Abstract:

    Crushing Plants are widely used around the world as a pre-processing step in the mineral and mining industries or as standalone processing Plants for final products in the aggregates industry. Despite automation and different types of advanced model predictive control, many the processes are still managed by operators. The skill of the operators influences the process performance and thus production yield. Therefore, it is important to train the operators so they know how to behave in different situations and to make them able to operate the process in the best possible way. Different types of models for crushers and other production units have been developed during the years and the latest improvement is the addition of dynamic behavior which gives the Crushing Plants a time dependent behavior and performance. This can be used as a simulator for operators training. By connecting an Internet based Human Machine Interface (WebHMI) to a dynamic simulator with the models incorporated, an on-line training environment for operators can be achieved. In this paper, a dynamic Crushing Plant simulator implemented in MATLAB/SIMULINK has been connected to a WebHMI. The WebHMI is accessible via the Internet, thus creating a realistic control room for operators’ training. In the created training environment, the operators can be trained under realistic conditions. Simple training scenarios and how they could be simulated are discussed. Apart from the increased level of knowledge and experience among the operators, the time aspect is an important factor. While a real Crushing Plant is still being built, the operators to be can already be trained, saving a lot of the commissioning and ramp up time.

  • Tuning of real-time algorithm for Crushing Plants using a dynamic Crushing Plant simulator
    2012
    Co-Authors: Erik Hulthén, Gauti Asbjörnsson, Carl Magnus Evertsson
    Abstract:

    Real-time algorithms have earlier been successfully implemented in Crushing Plants for the selection of set-points. The algorithms build on principle models of how the on-line adjustable parameters affect the process. The dynamics in a Crushing Plant are usually consequences of altered states of the Plant due to factors such as natural variation of the processed material, degrading equipment performance and more or less stochastic discrete events. Although the real-time algorithms are carefully designed in order to optimize the process, they are not fine-tuned themselves. In this paper a method for tuning real-time algorithms using a dynamic Crushing Plant simulator is presented. With the Plant realistically modeled in a dynamic simulator the constants of the real-time algorithm can be selected before the algorithm is implemented in a real Plant. Thus the algorithm can optimize the Plant better and quicker. The method is demonstrated with a simulation of a real Crushing Plant.

  • Output prediction of cone crushers
    Minerals Engineering, 1998
    Co-Authors: Carl Magnus Evertsson
    Abstract:

    The output prediction of cone crushers has been focused on both by the aggregate producing industry and the mining industry as the demands for higher quality and lower costs increase. In this paper a method for prediction of cone crusher performance is presented. By using the method both product size distributions and total capacity can be predicted. By combining these results a Crusher Performance Map (CPM) is obtained. The CPM is a description of crusher performance over a wide range of variation in the operational parameters. Therefore the CPM can be used for optimization and choice of operational machine parameters for an individual crusher as a part of a Crushing Plant. © 1998 Elsevier Science Ltd. All rights reserved.

Gauti Asbjörnsson - One of the best experts on this subject based on the ideXlab platform.

  • Crushing Plant Dynamics
    2015
    Co-Authors: Gauti Asbjörnsson
    Abstract:

    The performance of a Crushing Plant is an essential element in achieving efficient production of aggregates or metals. A Crushing Plant´s operating performance depends on the design and configuration of each individual process unit, the configuration of the Plant, the design of the control system, events occurring in the process and the physical properties of the incoming feed. The production process is a continuous process and as such it is also subjected to variations and changes in performance depending on the condition of the process. Crushing Plants however, are traditionally simulated with steady-state simulation models which are not capable of predicting these conditions. A different technique is therefore necessary in order to estimate the actual behaviour of the Plant with respect to time. Crushing Plants are affected by both gradual and discrete changes in the process over time which alters the performance of the entire system, making it dynamic. A dynamic simulation is defined in this thesis as continuous simulations with sets of differential equations with static equations to reproduce the dynamic performance of a system. In this thesis multiple operational issues have been identified in order to achieve adequate process fidelity for simulation purposes. These operational issues have been addressed by introducing methods and models for representing different dynamic aspects of the process. These include: different types of bins to handle misaligned feeding, segregation and different flow behaviour, the use of system identification to measure actuator response to accurately estimate unit response, wear estimation for crushers, mechanistic models for crushers and screens for more accurate estimation of unit dynamics, segmented conveyors that can estimate material flow for conveyors with variable speed drives, parameter selection for optimum process performance, discrete events that occur within the process and different control strategies to capture the process dynamics. Different applications for dynamic simulation have been explored and demonstrated in this thesis. These include: process evaluation, control development, process optimization, operational planning, maintenance scheduling and operator training. Each of these areas puts different constraints on the modelling of Crushing Plants and the level of fidelity, which is determined by the purpose of the simulation. In conclusion, dynamic simulation of production processes has the ability to provide the user with in-depth understanding about the simulated process, details that are usually not available with static simulations. Multiple factors can affect the performance of a Crushing Plant, factors that need to be included in the simulation to be able to estimate the actual Plant performance.

  • Modelling and simulation of dynamic Crushing Plant behavior with MATLAB/Simulink
    Minerals Engineering, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Every process is subjected to changes in performance and efficiency over time. These dynamics can originate upstream and be inherent through the process or occur anywhere in the downstream process. Traditional Plant simulations are performed with steady-state simulation, which are limited to give the performance in an ideal situation. However, Plant performance usually tends to deviate away from the predicted Plant performance. These dynamics are usually consequences of an altered state of the Plant due to factors such as natural variation, unmatched, inappropriate or degrading equipment performance and/or stochastic events. This paper presents a novel approach for simulating dynamic Plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink. An example of an existing Crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator. The results and knowledge gained from the simulation can provide a base for optimizing a robust production output in the form optimal utilization, energy efficiency or higher product quality.

  • modelling and simulation of dynamic Crushing Plant behavior with matlab simulink
    Minerals Engineering, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Every process is subjected to changes in performance and efficiency over time. These dynamics can originate upstream and be inherent through the process or occur anywhere in the downstream process. Traditional Plant simulations are performed with steady-state simulation, which are limited to give the performance in an ideal situation. However, Plant performance usually tends to deviate away from the predicted Plant performance. These dynamics are usually consequences of an altered state of the Plant due to factors such as natural variation, unmatched, inappropriate or degrading equipment performance and/or stochastic events. This paper presents a novel approach for simulating dynamic Plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink. An example of an existing Crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator. The results and knowledge gained from the simulation can provide a base for optimizing a robust production output in the form optimal utilization, energy efficiency or higher product quality.

  • An On-line Training Simulator Built on Dynamic Simulations of Crushing Plants
    IFAC Proceedings Volumes, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Carl Magnus Evertsson
    Abstract:

    Crushing Plants are widely used around the world as a pre-processing step in the mineral and mining industries or as standalone processing Plants for final products in the aggregates industry. Despite automation and different types of advanced model predictive control, many the processes are still managed by operators. The skill of the operators influences the process performance and thus production yield. Therefore, it is important to train the operators so they know how to behave in different situations and to make them able to operate the process in the best possible way. Different types of models for crushers and other production units have been developed during the years and the latest improvement is the addition of dynamic behavior which gives the Crushing Plants a time dependent behavior and performance. This can be used as a simulator for operators training. By connecting an Internet based Human Machine Interface (WebHMI) to a dynamic simulator with the models incorporated, an on-line training environment for operators can be achieved. In this paper, a dynamic Crushing Plant simulator implemented in MATLAB/SIMULINK has been connected to a WebHMI. The WebHMI is accessible via the Internet, thus creating a realistic control room for operators’ training. In the created training environment, the operators can be trained under realistic conditions. Simple training scenarios and how they could be simulated are discussed. Apart from the increased level of knowledge and experience among the operators, the time aspect is an important factor. While a real Crushing Plant is still being built, the operators to be can already be trained, saving a lot of the commissioning and ramp up time.

  • Tuning of real-time algorithm for Crushing Plants using a dynamic Crushing Plant simulator
    2012
    Co-Authors: Erik Hulthén, Gauti Asbjörnsson, Carl Magnus Evertsson
    Abstract:

    Real-time algorithms have earlier been successfully implemented in Crushing Plants for the selection of set-points. The algorithms build on principle models of how the on-line adjustable parameters affect the process. The dynamics in a Crushing Plant are usually consequences of altered states of the Plant due to factors such as natural variation of the processed material, degrading equipment performance and more or less stochastic discrete events. Although the real-time algorithms are carefully designed in order to optimize the process, they are not fine-tuned themselves. In this paper a method for tuning real-time algorithms using a dynamic Crushing Plant simulator is presented. With the Plant realistically modeled in a dynamic simulator the constants of the real-time algorithm can be selected before the algorithm is implemented in a real Plant. Thus the algorithm can optimize the Plant better and quicker. The method is demonstrated with a simulation of a real Crushing Plant.

Linda Pulungan - One of the best experts on this subject based on the ideXlab platform.

  • Evaluasi Produksi Crushing Plant terhadap Peningkatan Produksi di PT. Buana Nur Barokah Kecamatan Cimahi Kota Cimahi Jawa Barat
    2020
    Co-Authors: Octo Fredy Syahputra, Linda Pulungan, Sriyanti Sriyanti
    Abstract:

    Abstract. This research was intended to evaluate the production in the unit of Crushing Plant, therefore to improvement the increase of the production in PT. Buana Nur Barokah, Cimahi sub-district, Cimahi City, West Java, which currently its production target is 25,000 tons/month, and evaluate the things that caused the production of the target was not achieved. The problems gained in this end-task activities lie in the aspects that affect the production performance of the Crusher unit, among others: how long the resistance occurs in the unit of Crushing Plant. What amount of production is produced every crusher tool and the efficiency of crusher equipment on the unit of Crushing Plant. How much loose materials on the unit of Crushing Plant. Whether the selection of tools can meet the production targets. Based on the results of the research and observations in the field of the Crushing Plant unit at PT Buana Nur Barokah that the production target of 25,000 tons/month was not achieved due to problems that occurred during production activities due to bearing damage to the jaw crusher, replacement of the deck screening and repair of the rollers and rubber belts conveyor with a barrier time of 01.15 hours per day, natural factors can be caused by weather or rain with a time resistance of 0.06 hours per day. and humans factors are caused by the blockage of material inside the hopper due to the error of the dump truck operator when loading material into the hopper with a resistance time of 0.19 hours per day. Human factors can be caused by the blockage of material in the hopper due to operator error dump truck when loading material into the hopper with a resistance time of 0.19 hours per day. Therefore, from the observations and calculations, the company's production target of 25,000 tons / month was not achieved due to the effective time of the tool which was only 4.59 with an effectiveness of 60.59% hours/day for primary Crushing and effective time of the tool 6.8 with an effectiveness of 89.96% hours/day for secondary Crushing. also material entering the hopper is 20,912,9902 tons/month. Keywords: Crushing Plant, Roller, Hopper, Belt Conveyor , L oosematerials Abstrak. Penelitian ini bertujuan untuk mengevaluasi produksi di unit Crushing Plant , sehinga dapat dilakukan peningkatan produksi di PT Buana Nur Barokah Kecamatan Cimahi, Kota Cimahi, Jawa Barat, yang saat ini target produksinya 25.000 ton/bulan, dan mengevaluasi hal-hal yang menyebabkan tidak tercapainya target produksi tersebut. Permasalahan yang didapat dalam kegiatan tugas akhir ini terletak pada aspek yang mempengaruhi kinerja produksi unit crusher , antara lain : Berapa lama waktu hambatan yang terjadi pada unit Crushing Plant . Berapa jumlah produksi yang dihasilkan setiap alat crusher dan efisiensi alat crusher pada unit Crushing Plant . Seberapa besar loosematerials pada unit Crushing Plant . Apakah pemilihan alat dapat memenuhi target produksi. Berdasarkan hasil penelitian dan pengamatan di lapangan terhadap unit Crushing Plant di PT Buana Nur Barokah diketahui bahwa target produksi 25.000 ton/bulan tidak tercapai disebabkan masalah yang terjadi selama kegiatan produksi berlangsung yaitu  kerusakan bearing pada jaw crusher, penggantian deck screening dan perbaikan roller dan karet belt conveyor dengan waktu hambatan sebesar 01,15 jam per hari , Faktor alam dapat disebabkan oleh cuaca atau terjadinya hujan dengan waktu hambatan sebesar 0,06 jam per hari, dan faktor manusia disebabkan  terjadinya penyumbatan material di dalam hopper yang dikarenakan kesalahan operator dump truck pada saat memasukkan material ke dalam hopper dengan waktu hambatan sebesar 0,19 jam per hari. Maka dari hasil pengamatan dan perhitungan, target produksi perusahaan 25.000 ton/bulan tidak tercapai disebabkan oleh waktu efektif alat yang hanya 4.59 dengan efektifitas 60,59% jam/hari untuk primary Crushing dan waktu efektif alat 6.8 dengan 89,96% jam/hari untuk secondary Crushing . Selain itu juga material yang masuk ke hopper yaitu 20,912.9902 ton/bulan. Kata kunci : Crushing Plant, Roller, Hopper, Belt Conveyor, Loosematerials

  • Analisis Kinerja Unit Crushing Plant untuk Optimalisasi Produksi Batu Andesit di PT. Nurmuda Cahaya (Kontraktor PT. Budi Daya Remaja) Batujajar Timur Kecamatan Batujajar Kabupaten Bandung Barat Jawa Barat
    2020
    Co-Authors: Kevin Erwansyah Akbar, Linda Pulungan, Solihin Solihin
    Abstract:

    Abstract. Based on the conditions, the production target planned by the company was not reached. This can be caused by the factors of obstacles as well as the material loss factors that occur during the processing and distribution of materials. Therefore it is necessary to conduct a study of the Crushing Plant cycle unit in order to evaluate the performance of the tools used so that the company's production targets can be achieved. The research methodology used is by collecting data directly in the field and taking secondary data related to the processing of research data needed from various related sources. For data processing is done by calculating the efficiency of the tool work, the production of each tool, the reduction ratio, and the number of material losses that occur during the processing based on belt cut test data. Based on the results of research and data processing, it is known that the highest average obstacle time is at the secondary Crushing I stage 89,03 minutes/day (standby) and at the primary Crushing stage 9,72 minutes/day (repair). For the condition or condition of each tool and the effectiveness of its use it is known that the highest EU value is at the primary Crushing stage 76,99%, the highest AI value at the secondary Crushing I stage 97,76%, the highest PA is 98,25% at the secondary Crushing I stage and highest UA at 78,89% at the primary Crushing stage. For the results of the calculation of production based on the belt cut test it is known that the primary Crushing production is 105,45 tph, secondary Crushing I is 150 tph, secondary Crushing II is 49,54 tph, and sizing is 154,21 tph. The highest reduction ratio value is known as primary jaw crusher of 2.49 and categorized as medium RR.Not achieving the production target set by the company one of the factors is due to the highest losses of materials at primary Crushing stage 0,45 tph or 0,42% of the number of incoming feeds. Keywords: Crushing Plant, production, losses materials, efficiency, reduction ra tio Abstrak. Berdasarkan kondisi di lapangan, target produksi yang direncanakan oleh perusahaan tidak tercapai. Hal ini bisa disebabkan adanya faktor hambatan serta faktor losses material yang terjadi pada saat proses pengolahan maupun saat pendistribusian material. Oleh karena itu perlu dilakukan suatu penelitian terhadap siklus unit Crushing Plant demi mengevaluasi kinerja alat yang digunakan agar target produksi perusahaan dapat tercapai. Adapun metodologi penelitian yang digunakan yaitu dengan cara pengambilan data secara langsung di lapangan maupun pengambilan data sekunder yang terkait dengan pengolahan data penelitian yang dibutuhkan dari berbagai sumber terkait. Untuk pengolahan data dilakukan dengan cara memperhitungkan parameter availability dan efisiensi kerja alat, produksi masing-masing alat, reduction ratio , serta jumlah losses materials yang terjadi pada saat proses pengolahan berdasarkan data uji belt cut . Berdasarkan hasil penelitian dan pengolahan data, diketahui rata-rata waktu hambatan tertinggi yaitu pada tahap secondary Crushing I sebesar 89,03 menit/hari ( standby ) dan pada tahap primary Crushing sebesar 9,72 menit/hari ( repair ). Untuk keadaan atau kondisi masing-masing alat serta efektivitas penggunaannya diketahui bahwa nilai E.U tertinggi yaitu pada tahap primary Crushing sebesar 76,99%, nilai A.I tertinggi yaitu pada tahap secondary Crushing I sebesar 97,76%, P.A tertinggi sebesar 98,25% pada secondary Crushing I serta U.A tertinggi sebesar 78,89% pada primary Crushing. Untuk hasil perhitungan produksi uji belt cut diketahui bahwa produksi primary Crushing sebesar 105,45 tph, secondary Crushing I sebesar 150 tph, secondary Crushing II sebesar 49,54 tph, dan sizing sebesar 154,21 tph. Untuk nilai reduction ratio tertinggi diketahui yaitu pada alat primary jaw crusher sebesar 2,49 dan dikategorikan dalam kategori RR sedang. Tidak tercapainya target produksi yang ditetapkan oleh perusahaan salah satu faktornya karena adanya losses materials tertinggi yaitu pada tahapan sizing sebesar 0,45 tph atau 0,42% dari jumlah feed yang masuk. Kata Kunci: Crushing Plant, produksi, losses materials , efisiensi , reduction ratio

  • Analisis Kinerja Belt Conveyor untuk Menunjang Produktivitas Alat Crusher dan Optimalisasi Produksi di PT Silva Andia Utama, Jalan Pasir Paku, Kecamatan Batujajar, Kabupaten Bandung Barat, Provinsi Jawa Barat.
    2020
    Co-Authors: Maulana Gunawan, Linda Pulungan, Ahmad Machali Muchsin
    Abstract:

    A bstract. PT Silva Andia Utama, which is a supplier of andesite stone in West Java but does not have a consistent production every day in December and January, therefore it is necessary to do a work analysis of crusher units (Crusher) to optimize production targets in January. Reference work analysis of the crusher unit is based on the non-achievement of production targets in December of 700 tons / day. To consider this, it is necessary to evaluate the work of the andesite stone crusher. The parameters used in achieving the production target of PT Silva Andia Utama namely by conducting this evaluation activities include observations ranging from productive work time, time constraints, effective time, work efficiency of equipment, calculation of production of each unit of the Crushing Plant. The problems experienced by PT Silva Andia Utama are tool productivity and time constraints that occur in the Crushing Plant. At present the production produces split -5, + 3 cm, split -3, + 1 cm, and stone ash -1 cm. produce as much as an average of 686.13 tons / day while production is targeted at 700 tons / day, therefore the production target is not achieved. With this production target reaching 700 tons / day, the crusher unit was evaluated. From the observations from the field, the thing that really affects the achievement of production targets is that the hindering  factor of the tool is less effective at work. The amount of obstacles from production activities at the Crushing Plant at PT Mitra Multi Sejahtera was obtained at an average of 2.54 hours / day. The work effectiveness of the Crushing Plant is 3.66 hours / day and the working efficiency of the Crushing Plant is 54%. The biggest obstacle in this processing is the obstacle that occurs in tool repair due to damage during the production process, which is obtained from the calculation of 1.83 hours / day. As well as other obstacles that affect the production of human servants. All these obstacles must be minimized because they will have a major effect on increasing production. Keywords: Crushing Plant, Productivity Abstrak. PT Silva Andia Utama yang merupakan salah satu supplier batu andesit di jawa barat namun tidak memiliki konsistensi produksi tiap harinya pada bulan desember da januari maka dari itu perlu dilakukan analisis kerja unit alat peremuk (Crusher) untuk optimalisasi target produksi di bulan Januari. Acuan analisis kerja unit alat peremuk ini yaitu berdasarkan dengan ketidak tercapaiannya target produksi di bulan desember sebesar 700 ton/hari. Untuk mempertimbangkan hal tersebut maka diperlukan evaluasi kerja unit alat peremuk (crusher) batu andesit. Parameter yang digunakan dalam mencapai target produksi PT Silva Andia Utama yaitu dengan melakukan kegiatan evaluasi ini antara lain dilakukannya pengamatan mulai dari waktu kerja produktif,waktu hambatan, waktu efektif, efisiensi kerja  alat, perhitungan produksi setiap unit alat Crushing Plant. Permasalahan yang dialami oleh PT Silva Andia Utama adalah produktivitas alat serta waktu hambatan yang terjadi pada Crushing Plant. Pada saat ini produksi menghasilkan  split -5,+3 cm, split -3,+1 cm, dan abu batu -1 cm. menghasilkan sebanyak rata – rata 686,13 ton/hari sedangkan produksi ditargetkan sebanyak 700 ton/hari, maka dari itu target produksi tidak tercapai.  Dengan terjadinya ketidak capaian target produksi sebesar 700 ton/hari tersebut maka dilakukan evaluasi terhadap unit alat peremuk ini. Dari hasil pengamatan  dari lapangan hal yang sangat memperngaruhi ketidak tercapaian target produksi yaitu, faktor hambatan alat yang kurang efektif dalam bekerja. Adapun  Besar hambatan dari kegiatan produksi pada Crushing Plant di PT Mitra Multi Sejahtera didapat sebesar rata – rata 2,54 jam/hari. Efektifitas kerja pada alat Crushing Plant sebesar 3,66 jam/hari dan efisiensi kerja Crushing Plant sebesar 54 %. Hambatan terbesar pada proses pengolahan ini yaitu hambatan yang terjadi pada perbaiakan  alat akibat dari kerusakan saat proses produksi berjalan, dimana didapatkan dari hasil perhitungan sebesar 1,83 jam/hari. Serta hambatan lainnya yang mempengaruhi dari produksi yaitu hambatan manusia. Semua hambatan ini harus diminimalisir karena akan berpengaruh besar terhadap peningkatan produksi. Kata Kunci: Crushing Plant, Produktivitas

  • Evaluasi Kerja Unit Alat Peremuk (Crusher) Batu Andesit di PT Mitra Multi Sejahtera, Desa Mekarsari, Kecamatan Cikalong Kulon, Kabupaten Cianjur, Provinsi Jawa Barat
    2018
    Co-Authors: Ismail Yudantara, Linda Pulungan, Pramusanto Pramusanto
    Abstract:

    Ab st ra c t . Along with the development of very rapid development, be it the construction of highways, toll roads, buildings, housing, airfields, and other purposes, will certainly increase the demand for supporting materials, such as andesite stone. To overcome the increasing demand for andesite stone, in this case the mining process until the processing process should be considered as well as possible. The precipitation of andesite material especially in West Java has a large reserve potential, one of which is mined and processed by PT Mitra Multi Sejahtera yang located in Cikuya Village, Lagadar Village, Margaasih Subdistrict, Bandung Regency, West Java Province. The product of processing that has been done by PT Mitra Multi Sejahtera produce split 2 cm - 3cm, split 1 cm-2 cm, split 1.2 cm and stone ash 0,7 cm. The Crushing Plant unit used consists of hopper, feeder, jaw crusher, cone crusher, screen, and belt conveyor. Problems experienced by PT Mitra Multi Sejahtera is the productivity of tools and time constraints that occur in the Crushing Plant. At this time production produce split 2 cm - 3cm, split 1 cm-2 cm, split 1.2 cm and stone ash 0,7 cm. Produce 28000 tons / month m while production targeted as 30000 tons / month, therefore production target is not reached. With the occurrence of non-achievement of production targets of 30000 tons / month is then evaluated the unit of this crusher. From the results of observations from the field that greatly affects the lack of achievement of production targets that is, the inhibition factor is less effective tool in work. The major obstacles of production activities at the Crushing Plant at PT Mitra Multi Sejahtera gained of 0.87 hours / day. By doing the evaluation of the field production value that has been obtained for 32980.36 tons / month. The result of the jaw crusher tool arrangement that is used is open discharge of 200 mm has been reached from the target specified, then the steps must be done to maintain or optimize the premises of how to reduce the damage that occurs in the crsuhing Plant unit, especially on the jaw cusher. if the barriers are minimized then the production obtained is 35391.37 tons / month. Keywords: Crushing Plant, Productivity Abstrak. Seiring dengan berkembangnya pembangunan yang sangat pesat, baik itu pembangunan jalan raya, jalan tol, gedung-gedung, perumahan, lapangan terbang, dan keperluan lain, tentunya akan meningkatkan permintaan bahan penunjang, seperti halnya batu andesit. Untuk mengatasi permintaan batu andesit yang meningkat, dalam hal ini proses penambangan hingga proses pengolahan harus diperhatikan dengan sebaik mungkin. Endapan bahan galian andesit khususnya di Jawa Barat memiliki potensi cadangan yang cukup besar, salah satu diantaranya ditambang dan diolah oleh PT Mitra Multi Sejahtera yang berlokasi di Kampung Cikuya, Desa Lagadar, Kecamatan Margaasih, Kabupaten Bandung, Provinsi Jawa Barat. Produk dari pengolahan yang telah dilakukan PT Mitra Multi Sejahtera menghasilkan  split 2 cm – 3cm, split 1 cm-2 cm, split 1,2 cm dan abu batu 0,7 cm. Unit Crushing Plant yang digunakan terdiri dari hopper, feeder, jaw crusher, cone crusher, screen, dan belt conveyor. Permasalahan yang dialami oleh PT Mitra Multi Sejahteraadalah produktivitas alat serta waktu hambatan yang terjadi pada Crushing Plant. Pada saat ini produksi menghasilkan  split 2 cm – 3cm, split 1 cm-2 cm, split 1,2 cm dan abu batu 0,7 cm.menghasilkan sebanyak 28000 ton/bulan m sedangkan produksi ditargetkan sebanyak 30000 ton/bulan, maka dari itu target produksi tidak tercapai. Dengan terjadinya ketidak capaian target produksi sebesar 30000 ton/bulan tersebut maka dilakukan evaluasi terhadap unit alat peremuk ini. Dari hasil pengamatan  dari lapangan hal yang sangat memperngaruhi ketidak tercapaian target produksi yaitu, faktor hambatan alat yang kurang efektif dalam bekerja. Adapun  Besar hambatan dari kegiatan produksi pada Crushing Plant di PT Mitra Multi Sejahtera didapat sebesar 0,87 jam/hari. Dengan dilakukan nya evaluasi dilapangan nilai produksi yang telah didapatkan sebesar 32980,36 ton/bulan. Hasil pengaturan alat jaw crusher yang digunakan yaitu open discharge sebesar 200 mm sudah tercapai dari target yang ditentukan, maka langkah yang harus dilakukan untuk mempertahankan atau mengoptimalkan yaitu denga cara mengurangi hambtan yang terjadi pada unit crsuhing Plant terutama pada jaw cusher . apabila hambatan tersebut diminimalisir maka produksi yang didaptkan sebesar 35391,37 ton/bulan. Kata Kunci: Crushing Plant, Produktivitas

  • A Technical Study Of The Rock Crushing Plant Of Limestone Processing Unit For Fulfilling Cement Raw Material Production Target A Case Study Of The Crushing Plant Tuban-1 Operational Unit Of PT Semen Indonesia (Persero) Tbk Tuban Regency East Java Pro
    2017
    Co-Authors: Ivan Ivan, Zaenal Zaenal, Linda Pulungan
    Abstract:

    PT. Semen Indonesia as a cement company is one of the pillars of national cement industry. It plays a main role with a vision to being a leading company in Southeast Asia. Accordingly, it endeavors to increase significantly its production capacity in stages for cement production. The increasing cement production would be related to the effort of fulfilling raw materials in cement production.       There search objective was to : (1) find out the production of Crushing Plant now, (2) efforts of increasing Crushing Plant production for fulfilling production target, and (3) by change in the effective production time optimization for the production of cement raw material to be achieved. Ininitial condition, the company’s production target was 540,000 ton/month with a production target of 18,000 ton per day. However, the actual production per day achieved only 15,359.55 ton/day. Due to high market demands, the company should be capable of achieving its production target of 18,000 ton/month. In addition, given the increasing intense competition from other cement companies, the achievement of production target should be realized for winning cement market share. One of the attempts to do for achieving a production target of 54,000 ton/month is by enhancing performance, so that an increasing actual production target perday could be realized. This would also supported by the increasing working hours per day, increasing from an efficiency of 75.02% to be that of 88.77%. The company is now employing a computer-regulated VLC (Vanel Line Control) system. Therefore, when there is failure in one of the processing machines it can be simply controlled from the computer at Crushing Plant control room. After passing through a size reducing process by using Crushing Plant equipment the limestone would be going to a further stage as the main raw material of cement.

Erik Hulthén - One of the best experts on this subject based on the ideXlab platform.

  • Two Variable Real-Time Algorithm for Cone Crusher Control
    2017
    Co-Authors: Erik Hulthén, Carl Magnus Evertsson
    Abstract:

    Cone crushers are used in the mineral, mining, and aggregate industry for fragmentation of rock materials. Control systems for cone crusher setting (CSS) are widely used to compensate for wear and to protect the crusher. With a frequency converter the eccentric speed in a cone crusher can be adjusted in real-time. The eccentric speed of the main shaft affects the number of compressions the material is exposed to and thus the capacity and the particle size distribution of the product. By applying mass-fl ow sensors to the process, a feedback of the different product yields is obtained in every moment. In this paper, a model and an algorithm are presented. The algorithm takes the incrementally increasing CSS into account and compensates for this with a successively changing eccentric speed. In order to implement the algorithm, a monitoring and control system is developed, including the online algorithm for selection eccentric speed. The different product fl ows from the Crushing Plant are continuously monitored by mass fl ow meters. The fi tness function is set by the Plant management depending on production targets and market situation. An earlier developed Finite State Machine (FSM) algorithm is also implemented and evaluated in the system. The developed algorithm has been validated and verifi ed at a Crushing Plant for aggregates with a production of around 400 kton a year. The new algorithm is shown to increase the Crushing stage throughput with 6.9 per cent. The FSM algorithm, on the other hand, increases the throughput with 5.3 per cent, which is a confi rmation of the magnitude of its benefi ts demonstrated in an earlier paper.

  • Framework for material modelling in a processing Plant
    2015
    Co-Authors: Magnus Bengtsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Material modelling within a Crushing Plant is closely dependent on both manual and automatic operations as well as a close follow up on the utilization of the Plant performance from a management perspective. The desire to fully be able to utilize the Crushing Plant with respect e.g. to material handling is limited due to the lack of possibility to fully observe actions within the process. There are large quantities of data that can be monitored in the Crushing Plant SCADA system. However the data collected are governed by the quantity of actual sensors in the process. The aim with this paper is to propose a method for how-to pre-process the automatically gathered SCADA data in order to fill up dynamic models for process simulations. There is a fundamental need to increase the resolution of how the Crushing Plant behaves. This will be structured as a framework for analysing and suggesting model improvements that will increase the utilization and decrease both manual operations and give better performance when controlling the process.

  • Cost And Performance Optimization Of A Tertiary Crushing Stage
    2015
    Co-Authors: Magnus Bengtsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    There is increasing demand to optimise performance and profit of Crushing Plants. Research in this area has resulted in the development of numerous optimisation tools, and resent research has shown that the quality aspects of production have great influence on the optimisation results. The quality, cost, profit and capacity of a product is influenced by several parameters, and in order to control all of these parameters it is necessary to use some sort of optimisation software. In this paper, a novel approach use the parameters cost, profit, capacity and quality in order to perform a multi objective optimization of a Crushing Plant is presented. As an example a tertiary Crushing stage consistent of a cone crusher and a vertical shaft impact crusher (VSI) is used as base for the designed objective function. The process has a given set of constraints that represents the conditions normal in these type of Crushing applications. The first step in this paper is to identify if the range of the constraints can cause undesirable production costs when reaching for a given product property. The next step in the optimization shows how a strategy for relaxing constraint can increase overall productivity and still reach certain product properties. The conclusions made in this work are that multi objective optimization is essential when optimizing Crushing Plant production against multiple objectives. Relaxation of constraints can increase the overall performance of the Crushing Plant.

  • Modelling and simulation of dynamic Crushing Plant behavior with MATLAB/Simulink
    Minerals Engineering, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Every process is subjected to changes in performance and efficiency over time. These dynamics can originate upstream and be inherent through the process or occur anywhere in the downstream process. Traditional Plant simulations are performed with steady-state simulation, which are limited to give the performance in an ideal situation. However, Plant performance usually tends to deviate away from the predicted Plant performance. These dynamics are usually consequences of an altered state of the Plant due to factors such as natural variation, unmatched, inappropriate or degrading equipment performance and/or stochastic events. This paper presents a novel approach for simulating dynamic Plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink. An example of an existing Crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator. The results and knowledge gained from the simulation can provide a base for optimizing a robust production output in the form optimal utilization, energy efficiency or higher product quality.

  • modelling and simulation of dynamic Crushing Plant behavior with matlab simulink
    Minerals Engineering, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Every process is subjected to changes in performance and efficiency over time. These dynamics can originate upstream and be inherent through the process or occur anywhere in the downstream process. Traditional Plant simulations are performed with steady-state simulation, which are limited to give the performance in an ideal situation. However, Plant performance usually tends to deviate away from the predicted Plant performance. These dynamics are usually consequences of an altered state of the Plant due to factors such as natural variation, unmatched, inappropriate or degrading equipment performance and/or stochastic events. This paper presents a novel approach for simulating dynamic Plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink. An example of an existing Crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator. The results and knowledge gained from the simulation can provide a base for optimizing a robust production output in the form optimal utilization, energy efficiency or higher product quality.

Magnus Evertsson - One of the best experts on this subject based on the ideXlab platform.

  • Framework for material modelling in a processing Plant
    2015
    Co-Authors: Magnus Bengtsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Material modelling within a Crushing Plant is closely dependent on both manual and automatic operations as well as a close follow up on the utilization of the Plant performance from a management perspective. The desire to fully be able to utilize the Crushing Plant with respect e.g. to material handling is limited due to the lack of possibility to fully observe actions within the process. There are large quantities of data that can be monitored in the Crushing Plant SCADA system. However the data collected are governed by the quantity of actual sensors in the process. The aim with this paper is to propose a method for how-to pre-process the automatically gathered SCADA data in order to fill up dynamic models for process simulations. There is a fundamental need to increase the resolution of how the Crushing Plant behaves. This will be structured as a framework for analysing and suggesting model improvements that will increase the utilization and decrease both manual operations and give better performance when controlling the process.

  • Cost And Performance Optimization Of A Tertiary Crushing Stage
    2015
    Co-Authors: Magnus Bengtsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    There is increasing demand to optimise performance and profit of Crushing Plants. Research in this area has resulted in the development of numerous optimisation tools, and resent research has shown that the quality aspects of production have great influence on the optimisation results. The quality, cost, profit and capacity of a product is influenced by several parameters, and in order to control all of these parameters it is necessary to use some sort of optimisation software. In this paper, a novel approach use the parameters cost, profit, capacity and quality in order to perform a multi objective optimization of a Crushing Plant is presented. As an example a tertiary Crushing stage consistent of a cone crusher and a vertical shaft impact crusher (VSI) is used as base for the designed objective function. The process has a given set of constraints that represents the conditions normal in these type of Crushing applications. The first step in this paper is to identify if the range of the constraints can cause undesirable production costs when reaching for a given product property. The next step in the optimization shows how a strategy for relaxing constraint can increase overall productivity and still reach certain product properties. The conclusions made in this work are that multi objective optimization is essential when optimizing Crushing Plant production against multiple objectives. Relaxation of constraints can increase the overall performance of the Crushing Plant.

  • Modelling and simulation of dynamic Crushing Plant behavior with MATLAB/Simulink
    Minerals Engineering, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Every process is subjected to changes in performance and efficiency over time. These dynamics can originate upstream and be inherent through the process or occur anywhere in the downstream process. Traditional Plant simulations are performed with steady-state simulation, which are limited to give the performance in an ideal situation. However, Plant performance usually tends to deviate away from the predicted Plant performance. These dynamics are usually consequences of an altered state of the Plant due to factors such as natural variation, unmatched, inappropriate or degrading equipment performance and/or stochastic events. This paper presents a novel approach for simulating dynamic Plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink. An example of an existing Crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator. The results and knowledge gained from the simulation can provide a base for optimizing a robust production output in the form optimal utilization, energy efficiency or higher product quality.

  • modelling and simulation of dynamic Crushing Plant behavior with matlab simulink
    Minerals Engineering, 2013
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Every process is subjected to changes in performance and efficiency over time. These dynamics can originate upstream and be inherent through the process or occur anywhere in the downstream process. Traditional Plant simulations are performed with steady-state simulation, which are limited to give the performance in an ideal situation. However, Plant performance usually tends to deviate away from the predicted Plant performance. These dynamics are usually consequences of an altered state of the Plant due to factors such as natural variation, unmatched, inappropriate or degrading equipment performance and/or stochastic events. This paper presents a novel approach for simulating dynamic Plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink. An example of an existing Crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator. The results and knowledge gained from the simulation can provide a base for optimizing a robust production output in the form optimal utilization, energy efficiency or higher product quality.

  • A Training Simulator for Crushing Plant Operators
    2012
    Co-Authors: Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson
    Abstract:

    Crushing Plants are widely used around the world as a pre-processing step in the mineral and mining industries and as standalone processing Plants in the aggregates industry. Despite automation and different advanced model predictive control a lot of the process is still managed by operators. The operators affect a lot of the performance. The numbers of the improvement they can achieve are at least as big as the advanced control algorithms’, today. Therefore it is also important to train the operators so they know how to behave in different situations. Models for crushers and other production units have been developed during the years and the latest add is the different units’ dynamic behavior being brought in, which gives the Crushing Plants dynamic time dependant performance. This can be used as a simulator for operators training. By connecting a Human Machine Interface (HMI) to a dynamic simulator with the models incorporated, a training environment for operators can be achieved. In this paper a dynamic Crushing Plant simulator implemented in MATLAB/SIMULINK has been connected to an HMI via a PLC. The HMI is placed in a control room at the university and complemented with monitors showing sequences from the process connected to the simulations, thus creating a realistic control room for training. In the created training environment the operators can be trained under realistic conditions. Simple training scenarios and how they could be simulated are discussed. Apart from the increased level of knowledge and experience among the operators, the time is an important factor. While a real Crushing Plant is still being built, the operators to be can already be trained, saving a lot of the commissioning time.