3938
Real-time Particle Size Distribution System for
Cone Crusher Optimization
Haijie Li
FLSmidth A/S Vigerslev Allé 77, Copenhagen, Denmark
ABSTRACT: In comminution circuits, accurate knowledge of the particle size distribution (PSD) at various
stages is vital. Currently, the majority of mineral and crushing facilities rely on manual screening to determine
the material size, which demands significant human effort.
In our study, we integrated two PSD monitoring systems in a gravel plant to evaluate a cone crusher’s efficiency
in real-time. By simultaneously observing the feed and product, we can derive a more comprehensive analysis
of the crusher’s performance. Such dual observation offers insights into the effects of feed variations on the final
product, enabling refined control and enhancement of the crushing procedure.
INTRODUCTION AND BACKGROUND
Cone crushers are used in both the aggregate production
and mining sectors, where the primary objectives are to
enhance product quality and simultaneously lower produc-
tion costs. Due to the vital role that crushing plays in these
industries, there has been a consistent emphasis on moni-
toring crusher performance (Evertsson, 2000).
The output of a cone crusher is controlled by the
Closed Side Setting (CSS), which represents the minimum
distance between the mantle and concave at any given
height. This parameter determines the maximum stress that
can be applied to a particle of a specific size, thereby influ-
encing whether it will break and the resulting fragments’
sizes (Cleary 2017, Johansson 2017). Crusher wear has
also been correlated with crusher operating conditions for
real-time optimization of performance (Hulthén, 2011).
Nonetheless, monitoring real-time product size has always
been a challenging endeavor. Manual sampling from the
conveyor belt is not only labor-intensive but also insuf-
ficient for achieving real-time crusher optimization (Li,
2021).
To achieve real-time size monitoring, FLS in collabora-
tion with Tipco GmbH, is working to develop a depend-
able online system for crushing plants. This system would
explore possibilities for incorporating information on parti-
cle size distribution (PSD) into advanced process controls.
Tipco GmbH, a German public limited company,
offers a particle size distribution measurement system
called GeoScanner that can measure sizes ranging from
100 micrometers to 100 millimeters. This system can sub-
sequently be employed for various purposes such as process
control, process engineering, monitoring of the plant, and
quality management.
The GeoScanner provides real-time signals for moni-
toring the particle size distribution of crushed products
from a crusher. In line with this, Tipco GmbH has engaged
a GeoScanner for FLSmidth in the upcoming planned
investigations. This deployment is specifically aimed at
demonstrating the GeoScanner’s fundamental suitability
for real-time measurements of crushing plant rock PSD.
These investigations are taking place at the Kieswerk
Nivelstein gravel plant, owned by Heidelberger Cement,
Real-time Particle Size Distribution System for
Cone Crusher Optimization
Haijie Li
FLSmidth A/S Vigerslev Allé 77, Copenhagen, Denmark
ABSTRACT: In comminution circuits, accurate knowledge of the particle size distribution (PSD) at various
stages is vital. Currently, the majority of mineral and crushing facilities rely on manual screening to determine
the material size, which demands significant human effort.
In our study, we integrated two PSD monitoring systems in a gravel plant to evaluate a cone crusher’s efficiency
in real-time. By simultaneously observing the feed and product, we can derive a more comprehensive analysis
of the crusher’s performance. Such dual observation offers insights into the effects of feed variations on the final
product, enabling refined control and enhancement of the crushing procedure.
INTRODUCTION AND BACKGROUND
Cone crushers are used in both the aggregate production
and mining sectors, where the primary objectives are to
enhance product quality and simultaneously lower produc-
tion costs. Due to the vital role that crushing plays in these
industries, there has been a consistent emphasis on moni-
toring crusher performance (Evertsson, 2000).
The output of a cone crusher is controlled by the
Closed Side Setting (CSS), which represents the minimum
distance between the mantle and concave at any given
height. This parameter determines the maximum stress that
can be applied to a particle of a specific size, thereby influ-
encing whether it will break and the resulting fragments’
sizes (Cleary 2017, Johansson 2017). Crusher wear has
also been correlated with crusher operating conditions for
real-time optimization of performance (Hulthén, 2011).
Nonetheless, monitoring real-time product size has always
been a challenging endeavor. Manual sampling from the
conveyor belt is not only labor-intensive but also insuf-
ficient for achieving real-time crusher optimization (Li,
2021).
To achieve real-time size monitoring, FLS in collabora-
tion with Tipco GmbH, is working to develop a depend-
able online system for crushing plants. This system would
explore possibilities for incorporating information on parti-
cle size distribution (PSD) into advanced process controls.
Tipco GmbH, a German public limited company,
offers a particle size distribution measurement system
called GeoScanner that can measure sizes ranging from
100 micrometers to 100 millimeters. This system can sub-
sequently be employed for various purposes such as process
control, process engineering, monitoring of the plant, and
quality management.
The GeoScanner provides real-time signals for moni-
toring the particle size distribution of crushed products
from a crusher. In line with this, Tipco GmbH has engaged
a GeoScanner for FLSmidth in the upcoming planned
investigations. This deployment is specifically aimed at
demonstrating the GeoScanner’s fundamental suitability
for real-time measurements of crushing plant rock PSD.
These investigations are taking place at the Kieswerk
Nivelstein gravel plant, owned by Heidelberger Cement,