1. 2013 Management Workshop Georgia Crushed Stone Association Optimize Fine Cone Crushing Circuits Using Automation

2. Presentation Summary In today’s market the demand for fine aggregates has risen. Many crushing plants have added or modified crushing circuits to increase the production of minus 3/8” rock typically used in asphalt. Automation packages ensure you maximize cone productivity while protecting the machine from overload.

3. The Challenge Receive a fine feed gradation –Minus 1-1/2” or 2” –Allow for varied feed gradations depending on inventory balance Produce fine products –½” minus, 3/8” minus, MFG sand Maximize production while protecting the crusher

4. Cone Feed Video

5. Cone Discharge Video

6. Things We Need to Understand What happens in the crushing chamber Mechanical limits of fine crushing What data can be collected from crusher systems What a good cone applications is How does fine crushing affect performance

7. Ideal - Evenly Graded Feed Best Performance – reduction & TPH –90 to 100 percent passing the closed side feed opening. –40 to 60 percent passing the mid point of the crushing chamber. –0 to 10 percent passing the crusher setting.

8. Benefit of a well graded feed. Allows for effective Inter-Particle Crushing Need room for expansion (voids)

9. What We Have in Fine Crushing Fine material fills the voids between the coarser stone. The crushing stroke compresses the material, eliminating any voids and packing material into a solid mass. (most sensitive at smaller settings)

10. Crusher Overload in Fine Crushing “Packing / Float”

11. Liners Typically a “fine” chamber is used Temporary situation –Make due with what’s in the crusher –Live with issues CSS Short liner life Output gradation

12. Match Profile to Feed

13. Two Areas for Automation Cone Automation –Collect sensor information –Make decision to protect the machine and continue operation –Assume some human decisions Plant Automation –Integrate multiple pieces of equipment to act in unison and optimize production –Reduce need for human interaction in the plant operation

14. Benefits of Cone Crusher Automation Change crusher setting remotely Automatic liner calibration Protects from overload conditions Tracks liner wear Logs and trends data Versatile Minimizes installation costs Highly effective troubleshooting tool

15. Ethernet Communication Hub is located inside PLC enclosure. Optional Modem Ethernet Network DeviceNet Network Optional USB Printer Select list of printers Typical Components

16. Crusher Protection Oil temp & flow Hydraulic temp & pressure Alarms and interlocks Auto protect (open setting) –Amp draw –Bowl float Maintenance

17. Troubleshooting Alarm history Trending reports Communicate with factory

18. Liner Life & Calibration

19. TRAC10 ® Trending

20. TRAC10 ® Alarm History

21. Today’s Cones in Fine Crushing Video

22. Today’s Cones - Settings Variables that affect settings –Feed gradation –Moisture in feed –Screening efficiency –Specification requirements of finished product –Depth of choke feed above head Goal is to utilize horsepower to the fullest extent while protecting the crusher

23. Cone Automation = Optimum setting & Optimum Production

24. What is the “Optimum” CSS Worth? NO automation –Run cone at.70” CSS –This is “Safe” setting –Never an issue –Don’t need to watch too close –Makes 155 TPH 3/8” x 0 Automated cone –Runs 90% of the time at.60” CSS (10% at.70”) –This is “Optimum” setting –Makes 165 TPH 3/8 x 0 when at.60” CSS –18,000 extra tons per year ($$$,$$$)

25. CSS Optimization Manual set back –Indicator notice or light Auto return on timer –Periodic return to set point

26. Try Different Levels in Cone What gives you the best output gradation –Lower depth of material & tighter setting –More depth and larger setting Feed gradation changes –As gradation changes voids in chamber change

27. Vary the Feed Gradation Coarser Feed –More voids –Tighter CSS –Lower AMP draw Finer Feed –Less room for expansion = packing –Higher AMP draw –May generate more sand

28. Plant Automation Level sensor in cone Level sensor in bin Communicates with surge feeders Cone overflow chutes with presence detector Belt scales Zero speed switches

29. Plant Automation – PID Controllers Proportional-integral-derivative Controllers –PID controller calculates an "error" value as the difference between a measured process variable and a desired set point. –The controller attempts to minimize the error by adjusting the process control inputs. –PID controller can be used to control any process which has a measurable output, a known ideal value for that output and an input to the process that will affect the relevant measureable output –Thinks for us so we don’t have to stare at cameras and spin dials all day

30. Controllers communicate with –Feeder VFD’s –Level sensors –Belt scales –Crusher AMP outputs Logic is developed specific to your crushing circuit Plant Automation – PID Controllers

31. Plant Automation Sensing & Feedback Devices Laser Radar Ultrasonic Tilt Switches Presence detector Zero speed switch

32. Plant Automation Sensing & Feedback Devices Variables that determine what level sensor is used –Distance from target –Range of measurement –Lump size of particles –Flow of material into bin or chamber –Dust Radar common in bins Laser common in crusher chamber

33. Laser level sensor in cone chamber Ultrasonic Laser Track Plants

34. Radar Sensor used for bin level. Tilt Switch – overflow protection

35. Don’t Forget Your Screening Account for heavier recirculation loads –35-40% vs 15-20% –Consider one size larger than normal –May use two decks to cut topsize Split loads, reduce bed depth –Check speed & stroke on screen Weigh pros and cons of wet or dry screening Specialty media

36. Process Flow Software doesn’t Tell the Whole Story Software takes the incoming TPH and applies it to the manufacturers published output gradation Using software you can feed sand to a cone and make 89’s (may get a warning) Experience is a big part of the equation

37. Process Flow Software doesn’t Tell the Whole Story in Fine Crushing The fine cone crusher: – will find the setting it wants to run at not the software –setting will likely be greater than the desired P-100 (100% passing) –will likely reach the published TPH at the operating CSS –output gradation will not match the published output gradation at the operating CSS

38. Estimating Net Finish Product In a Fine Crush Application (A) Determine where crusher runs at based on auto-protect control (consult manufacturer) (B) Determine average opening of screen cloth determining top size of product Determine published capacity TPH midpoint of crusher at the CSS Reduce published TPH midpoint 8% +/- per 1/16” differential between (A) & (B)

39. Estimating Net Finish Product Example (A) Crusher runs at.625” (per manufacturer) (B) Product is cut on.375” wire cloth Published midpoint capacity at 5/8” CSS is 257 TPH (225-290 range) Differential between A & B is.250” or 4 / 16 4 x 8% = 32% is the differential between gross and net finish product 257 TPH – 32% = 175 TPH net finished product (3/8” x 0)

40. Create & Understand Your Constant Benchmark existing equipment –Individual machine performance Optimize existing circuit –Change one thing at a time & re-measure –Test circuit / test theory Study material specifications –Talk to your customers –Gradation specifications –Cubicity requirements Automate the areas that require the highest level of human process monitoring

41. QUESTIONS?