3/4/2015 CONE CRUSHER OPTIMIZATION. Abram Woodward Plant Manager Anderson Creek Martin Marietta

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1 CONE CRUSHER OPTIMIZATION Abram Woodward Plant Manager Anderson Creek Martin Marietta 1

2 Learning Objectives How to Define Your Crusher s Performance How to Your Optimal Setting How to Maximize Your Performance Through Liner Selection Project Background Market Change in 2011 VA #8 s to VA 57 s and 67/68 s Reduce 3/8 minus and increase ½ x 1-1/4 Limited Sales for Crusher Dust or Manufactured Sand Natural Sand Prevalent in the Market Continual Process Improvement How Do We Do More With Less? Improve Safety Increase Profitability Customer Service Maximize Products Customers Need 2

3 About The Crusher Pegson AUTOMAX 1000 (A Terex Brand) In Tertiary Position in Secondary Plant Through Gates/Chutes Able to Increase/Decrease Feed Quantity vs Close Circuit to Omnicone Bin Level Laser Sensor to Turn Feed Belt On/Off Crusher Level Laser Sensor to Measure Feed in Crusher to Speed Up/Slow Down Feed Belt Crusher is Belt Driven Metric Motor, V-Belts Motor has Soft Start Controlled through WonderWare Automation/ GE Genius Blocks Hydraulic Adjustment, Tramp Release Linear Position Sensor for Setting Control Pad s Hours, Setting, Liner Wear Estimation One of a Handful in a Stationary Application and Martin Marietta Network The Overall Process Assess Current Situation Bottlenecks Set Benchmarks and Goals for Measurement Low Cost Immediate Changes vs. Long Term Expensive Changes Settings,, Feed Size/Rate Bowls, Machine, Motor, etc. Identify Resources for the Project Implement Change Record / Modify Goals 3

4 Defining Crusher Performance Production Related: Tons per Hour Reduction Ratio Actual Output versus Desired Output Cost Related: Running Amps Compared to Maximum Crusher Availability Cost of Liner Change Learning Objectives How to Define Your Crusher s Performance How to Your Optimal Setting How to Maximize Your Performance Through Liner Selection 4

5 Finding Optimal Setting Initial Setting AggFlow Simulation Crusher Handbook Previous Settings Fine Tuning Your Setting Belt Cuts Before and After Using Foil Balls to Check Actual Setting Watching Crusher Amps Finding Optimal Setting Use AggFlow to Run iterations at different settings once model is complete CLOSED LOOP PEGSON 5

6 Finding Optimal Setting Initial Setting AggFlow Simulation Crusher Handbook Previous Settings Fine Tuning Your Setting Belt Cuts Before and After Using Foil Balls to Check Actual Setting Watching Crusher Amps Finding Optimal Setting Initial Setting AggFlow Simulation Crusher Handbook Previous Settings Fine Tuning Your Setting Belt Cuts Before and After Using Foil Balls to Check Actual Setting 6

7 Finding Optimal Setting Initial Setting AggFlow Simulation Crusher Handbook Previous Settings Fine Tuning Your Setting Belt Cuts Before and After Using Foil Balls or Lead to Check Actual Setting It s better to make frequent small adjustments than one daily adjustment to help with product consistency, shape, and quality With high head spin it is best to check as soon as the crusher clears Learning Objectives How to Define Your Crusher s Performance How to Your Optimal Setting How to Maximize Your Performance Through Liner Selection 7

8 Liner Selection The Wrong Liner Will Result in Uneconomical Wear of the Wrong Profile, Metallurgy, Poor Wear Life Cause Inefficient Crushing Low Reduction Ratio and Poor Gradation Cause Machine Abuse Running too tight or open, balance issues, brass wear Choosing the Right Liner Will Result in Low Cost and Higher Quality Production Optimize the Use of Your Machine, Power, and Manpower Provide You with an Optimal Gradation for that Plant Stage Reduce Time Spent Dealing with Your Machine Liner Selection It s a Process Profiles Vendor 8

9 Profiles Vendor Liner Profiles Selection Vendor - Manganese Manganese Percentage Be aware of the Percent Manganese when Comparing and Wear profiles. We used 18% with Frogswitch Lower percentages are easier to produce Higher percentages are more expensive due to make-up Higher percentages Wear longer, can be more brittle, and take longer to break in 9

10 Profiles Vendor Other Profiles Liner Enhancements Stepped vs. Smooth Standard Crusher Benefits Secondary Position Larger Feed Short-head Crusher Benefits Tertiary Crusher Finer Feed Profiles Vendor Key to Collect: Date Installed/Date Removed Weight of Set Before/After Tons Processed Operational Hours 10

11 Profiles Vendor Typical Wear Profile Set 2 in Test (Frogswitch) Paschal can measure Profile without cutting a section! Note cupping at discharge and elongated parallel zone Typical Wear Profile Set 3 in Test (Pegson) Profiles Vendor 11

12 % 21% 66% Profiles Vendor Assumptions: Based on 66% Utilized Case Previous Slide $10,000 set of Weighing 2000 lbs. Estimated 220 lbs/month of Mg Wear (1320 lbs in 6 months) 12

13 Profiles Vendor Based on Information Gathered a New Set is Designed Alternating New Sets with Previous Sets Already On Hand Return to Step to Ensure Change was Successful Have Vendor Profile the Used Set and Compare Profiles Safety Improvement 13

14 The Returns on Your Investment of Time and Money Saving 1 liner change per year $35,000 on 500,000 tons of annual production is 7.0 cent/ton savings. On $7 CTP = 1% Savings. You add 1.5 months of wear to your liner set at an Average of 42,000/month $35k/210k=$0.17/ton Equals 63,000 more tons/set or $35k/273k=$0.13 Saving Your Crew Extra Work AND Reducing Safety & Health Risks PRICELESS Improving your Crushing Performance Increased Manganese use From 66% Wear per set to 75% Wear (Thickness) Improving the Efficiency of your Machine and Operation Better Use of Electricity, Machine, and Man-hours In Our Case, a Better Quality Product Maximized for Our Sales Demand Additional Process Improvements Feeder Speed Variable Speed Drive Running at 100% and Not Covering Head By Decreasing the Gearbox Input Sheave We Increased the Max Speed of Feeder Belt Increased efficiency of crushing process Adjusted Laser Level Probe to Allow More Over the Head Set Warning Level in Automation to Allow Speed Decrease at 90% Adjusted Feed to Crusher to Keep Crusher Working Head speeds up when empty and horizontal scarring was found on liner from material hitting head at high speed frequently before it became choked. Choke Feeding to help reduce Flatness and Elongation (F&E) and improve Fractured Faces 14

15 Other Performance Characteristics Countershaft Speed Stay within Manufacturer s Specification The speed determines the number of blows the rock receives before exiting Higher Speeds = More Blows Slower speeds increase the chance for a stall and increase retention which decreases TPH Higher speeds can affect balance and oil cooling capabilities. Power Consumption Tighter settings result in higher power consumption Watching Amps while running can let you know if adjustments should be considered Liner Break-In Realize that the Manganese has a work-hardening period. Don t expect full production right away. Some Manufacturers have a recommended break-in process. Break-In is also about rounding edges to increase flow through cavity Thanks to These Industry Partners for Improving our Process Paschal Associates Drew Barksdale FROGSWITCH Alf Basson District and Division Support at Martin Marietta 15

16 What Questions Do You Have? Martin Marietta Abram Woodward Paschal Associates Drew Barksdale The Frog, Switch & Manufacturing Company Alf Basson 16