3895
Application of Dynamic Process Simulation for Optimizing Bin
Sizes of Crushing Plants
Kanishk Bhadani, Gauti Asbjörnsson, Magnus Evertsson
Department of Industrial and Materials Science, Chalmers University of Technology, Gothenburg, Sweden
ABSTRACT: Crushing plant operational performance is dynamic with coupled effects between varying capacity
of equipment and time-dependent (continuous or discrete) phenomenon which is balanced by buffers in the
form of bin placements together with control systems. The design of crushing plants greatly affects the dynamic
operating performance, particularly the size and placement of bins. The bin size is a significant contribution
to the investment cost and its size needs to be optimized to meet operational targets. This paper presents an
application method of integrating dynamic process simulation for the design of a suitable bin size in a complex
circuit configuration. A conceptual case study is used to demonstrate the optimization of bin sizing to maximize
equipment utilization and circuit mass flow. The results present design strategies for bin size selection based on
the intricate relationship established between equipment selection, circuit configuration, control system and
bin size.
Keywords: comminution process design dynamic simulation crushing screening bin sizing
INTRODUCTION
Coarse comminution and classification processes in miner-
als processing are highly dynamic in operation, meaning
the mass flow at different points in the circuit fluctuates.
The fluctuations in mass flow have multiple causes, for
example, frequency of run-of-mine (ROM) material feed
into the circuit, operational capacity of the different crush-
ers based on settings, varying performance of screens due
to changing load conditions and rated conveyor capacity
limits. To balance the circuit for stable performance and
safety requirements, buffers such as bins and stockpiles
with feeders are added together with the base layer control
system (on/off and PI controller). Buffers add the func-
tion of decoupling section and minimize interdependen-
cies. Buffers in the form of bins are usually added before
the crusher and screen equipment to control the operation.
The interlocks and safety requirements together with the
selected capacity of the buffers still lead to stops in the pro-
cess leading to production losses compared to the designed
process capacity. In most applications today, the comminu-
tion circuit is designed (equipment selection) using steady-
state simulation which does not look at the dynamics in
process operation.
The sizing of the bins used as buffers plays a vital role in
the design of a plant. For example, a smaller bin size means
a smaller buffer time before the interlock in the plant kick-
in, while adding larger buffer storage leads to increased
capital investment as the civil infrastructure requirement
is relatively increased. Changing machine settings due to
changes in ore characteristics leads to further differences
in the dynamic behaviour of the circuit. For example, the
mass flow of different streams will change leading to a
Application of Dynamic Process Simulation for Optimizing Bin
Sizes of Crushing Plants
Kanishk Bhadani, Gauti Asbjörnsson, Magnus Evertsson
Department of Industrial and Materials Science, Chalmers University of Technology, Gothenburg, Sweden
ABSTRACT: Crushing plant operational performance is dynamic with coupled effects between varying capacity
of equipment and time-dependent (continuous or discrete) phenomenon which is balanced by buffers in the
form of bin placements together with control systems. The design of crushing plants greatly affects the dynamic
operating performance, particularly the size and placement of bins. The bin size is a significant contribution
to the investment cost and its size needs to be optimized to meet operational targets. This paper presents an
application method of integrating dynamic process simulation for the design of a suitable bin size in a complex
circuit configuration. A conceptual case study is used to demonstrate the optimization of bin sizing to maximize
equipment utilization and circuit mass flow. The results present design strategies for bin size selection based on
the intricate relationship established between equipment selection, circuit configuration, control system and
bin size.
Keywords: comminution process design dynamic simulation crushing screening bin sizing
INTRODUCTION
Coarse comminution and classification processes in miner-
als processing are highly dynamic in operation, meaning
the mass flow at different points in the circuit fluctuates.
The fluctuations in mass flow have multiple causes, for
example, frequency of run-of-mine (ROM) material feed
into the circuit, operational capacity of the different crush-
ers based on settings, varying performance of screens due
to changing load conditions and rated conveyor capacity
limits. To balance the circuit for stable performance and
safety requirements, buffers such as bins and stockpiles
with feeders are added together with the base layer control
system (on/off and PI controller). Buffers add the func-
tion of decoupling section and minimize interdependen-
cies. Buffers in the form of bins are usually added before
the crusher and screen equipment to control the operation.
The interlocks and safety requirements together with the
selected capacity of the buffers still lead to stops in the pro-
cess leading to production losses compared to the designed
process capacity. In most applications today, the comminu-
tion circuit is designed (equipment selection) using steady-
state simulation which does not look at the dynamics in
process operation.
The sizing of the bins used as buffers plays a vital role in
the design of a plant. For example, a smaller bin size means
a smaller buffer time before the interlock in the plant kick-
in, while adding larger buffer storage leads to increased
capital investment as the civil infrastructure requirement
is relatively increased. Changing machine settings due to
changes in ore characteristics leads to further differences
in the dynamic behaviour of the circuit. For example, the
mass flow of different streams will change leading to a