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Prof. Erik Hulthén
Chalmers University of Technology

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0 Simulations
0 Real-Time Optimization
0 Cone crusher
0 Crushing plant

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Journal article
Published: 25 August 2021 in Minerals
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There is a need within the production industry for digitalization and the development of meaningful functionality for production operation. One such industry is aggregate production, characterized by continuous production operation, where the digital transformation can bring operational adaptability to customer demand. Dynamic process simulations have the ability to capture the change in production performance of aggregate production over time. However, there is a need to develop cost-efficient methodologies to integrate calibrations and validation of models. This paper presents a method of integrating an experimental and data-driven approach for calibration and validation for crushing plant equipment and a process model. The method uses an error minimization optimization formulation to calibrate the equipment models, followed by the validation of the process model. The paper discusses various details such as experimental calibration procedure, applied error functions, optimization problem formulation, and the future development needed to completely realize the procedure for industrial use. The validated simulation model can be used for performing process planning and process optimization activities for the crushing plant’s operation.

ACS Style

Kanishk Bhadani; Gauti Asbjörnsson; Barbara Schnitzer; Johannes Quist; Christian Hansson; Erik Hulthén; Magnus Evertsson. Applied Calibration and Validation Method of Dynamic Process Simulation for Crushing Plants. Minerals 2021, 11, 921 .

AMA Style

Kanishk Bhadani, Gauti Asbjörnsson, Barbara Schnitzer, Johannes Quist, Christian Hansson, Erik Hulthén, Magnus Evertsson. Applied Calibration and Validation Method of Dynamic Process Simulation for Crushing Plants. Minerals. 2021; 11 (9):921.

Chicago/Turabian Style

Kanishk Bhadani; Gauti Asbjörnsson; Barbara Schnitzer; Johannes Quist; Christian Hansson; Erik Hulthén; Magnus Evertsson. 2021. "Applied Calibration and Validation Method of Dynamic Process Simulation for Crushing Plants." Minerals 11, no. 9: 921.

Journal article
Published: 24 August 2021 in Sustainability
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This paper has two aims: to describe the current status and challenges of aggregates producers regarding the analysis and communication of environmental information of their products and to present a layout of a pre-verified tool with simulation capabilities that could assist aggregates producers with their environmental goals. Semi-structured interviews were conducted with three Swedish aggregates producers, an aggregates customer, and an expert agency. Additionally, published Environmental Product Declarations (EPDs) for aggregates and the EN 15804:2012 + A2:2019 were studied to reveal current practices and upcoming changes due to the updated standard. The synergies with process simulations were explored as a step towards using the EPD framework for continuous improvement of aggregates production. The interviews indicated that the main challenge for aggregates producers is the lack of easily available plant data for environmental calculations and clearly defined environmental goals at each plant. The proposed tool uses a common process flowsheet for both EPDs and simulations and has a pre-defined LCA module. The use of such a tool is expected to raise the environmental interest at aggregates plants and improve collaboration with LCA experts. Since the analysis is based on the Swedish aggregates market, the interview results are not directly generalizable to the European context.

ACS Style

Panagiota Papadopoulou; Diego Peñaloza; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Development of a Pre-Verified EPD Tool with Process Simulation Capabilities for the Aggregates Industry. Sustainability 2021, 13, 9492 .

AMA Style

Panagiota Papadopoulou, Diego Peñaloza, Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Development of a Pre-Verified EPD Tool with Process Simulation Capabilities for the Aggregates Industry. Sustainability. 2021; 13 (17):9492.

Chicago/Turabian Style

Panagiota Papadopoulou; Diego Peñaloza; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2021. "Development of a Pre-Verified EPD Tool with Process Simulation Capabilities for the Aggregates Industry." Sustainability 13, no. 17: 9492.

Article
Published: 27 July 2021 in Proceedings of the Design Society
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A comminution process is a material size reduction and separation process which is primarily used in the aggregates and the minerals processing industry. Knowledge related to equipment’s operation, raw material properties, operational strategies, control system, maintenance, etc. is needed to design a capable plant. New needs are arising from the industry for existing operational crushing plants such as investigation for improvements, upscaling, and downscaling of the capacity. The paper presents an application of simulation-driven development for a crushing plant in an existing gold processing plant. Due to the change in ore characteristics and the need for optimizing the cost of operation, it is required to investigate the opportunities for improvement and alternative options for downscaling the capacity of the plant. A systematic process for configuring, developing, and evaluating alternative concepts using a process simulation tool is presented. The results show the process of generating knowledge for alternative crushing plant operation settings and how the choices can be selected and eliminated using boundary conditions. The evaluation presents possible improvements and alternative concepts with their opportunities and pitfalls.

ACS Style

Kanishk Bhadani; Gauti Asbjörnsson; Paul Bepswa; Aubrey Mainza; Elibariki Andrew; Jisenha Philipo; Nkanyiso Zulu; Anthony Anyimadu; Erik Hulthén; Magnus Evertsson. SIMULATION-DRIVEN DEVELOPMENT FOR COARSE COMMINUTION PROCESS - A CASE STUDY OF GEITA GOLD MINE, TANZANIA USING PLANTSMITH PROCESS SIMULATOR. Proceedings of the Design Society 2021, 1, 2681 -2690.

AMA Style

Kanishk Bhadani, Gauti Asbjörnsson, Paul Bepswa, Aubrey Mainza, Elibariki Andrew, Jisenha Philipo, Nkanyiso Zulu, Anthony Anyimadu, Erik Hulthén, Magnus Evertsson. SIMULATION-DRIVEN DEVELOPMENT FOR COARSE COMMINUTION PROCESS - A CASE STUDY OF GEITA GOLD MINE, TANZANIA USING PLANTSMITH PROCESS SIMULATOR. Proceedings of the Design Society. 2021; 1 ():2681-2690.

Chicago/Turabian Style

Kanishk Bhadani; Gauti Asbjörnsson; Paul Bepswa; Aubrey Mainza; Elibariki Andrew; Jisenha Philipo; Nkanyiso Zulu; Anthony Anyimadu; Erik Hulthén; Magnus Evertsson. 2021. "SIMULATION-DRIVEN DEVELOPMENT FOR COARSE COMMINUTION PROCESS - A CASE STUDY OF GEITA GOLD MINE, TANZANIA USING PLANTSMITH PROCESS SIMULATOR." Proceedings of the Design Society 1, no. : 2681-2690.

Journal article
Published: 14 April 2021 in Minerals
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Process optimization and improvement strategies applied in a crushing plant are coupled with the measurement of such improvements, and one of the indicators for improvements is the mass flow at different parts of the circuit. The estimation of the mass flow using conveyor belt power consumption allows for a cost-effective solution. The principle behind the estimation is that the power draw from a conveyor belt is dependent on the load on the conveyor, conveyor speed, geometrical design, and overall efficiency of the conveyor. Calibration of the power-based belt scale is carried out periodically to ensure the accuracy of the measurement. In practical implementation, certain conveyors are not directly accessible for calibration to the physical measurement as these conveyors have limited access or it is too costly to interrupt the ongoing production process. For addressing this limitation, a better strategy is needed to calibrate the efficiency of the power-based belt scale and maintain the reliability of such a system. This paper presents the application of an optimization method for a data collection system to calibrate and maintain accurate mass flow estimation. This includes calibration of variables such as the efficiency of the power-based belt scale. The optimization method uses an error minimization optimization formulation together with the mass balancing of the crushing plant to determine the efficiency of accessible and non-accessible conveyors. Furthermore, a correlation matrix is developed to monitor and detect deviations in the estimation for the mass flow. The methods are applied and discussed for operational data from a full-scale crushing plant.

ACS Style

Kanishk Bhadani; Gauti Asbjörnsson; Erik Hulthén; Kristoffer Hofling; Magnus Evertsson. Application of Optimization Method for Calibration and Maintenance of Power-Based Belt Scale. Minerals 2021, 11, 412 .

AMA Style

Kanishk Bhadani, Gauti Asbjörnsson, Erik Hulthén, Kristoffer Hofling, Magnus Evertsson. Application of Optimization Method for Calibration and Maintenance of Power-Based Belt Scale. Minerals. 2021; 11 (4):412.

Chicago/Turabian Style

Kanishk Bhadani; Gauti Asbjörnsson; Erik Hulthén; Kristoffer Hofling; Magnus Evertsson. 2021. "Application of Optimization Method for Calibration and Maintenance of Power-Based Belt Scale." Minerals 11, no. 4: 412.

Journal article
Published: 31 December 2020 in Minerals
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The worldwide shortage of natural sand has created a need for improved methods to create a replacement product. The use of vertical shaft impact (VSI) crushers is one possible solution, since VSI crushers can create particles with a good aspect ratio and smooth surfaces for use in different applications such as in construction. To evaluate the impact a VSI crusher has on the process performance, a more fit-for-purpose model is needed for process simulations. This paper aims to present a modelling framework to improve particle breakage prediction in VSI crushers. The model is based on the theory of energy-based breakage behavior. Particle collision energy data are extracted from discrete element method (DEM) simulations with particle velocities, i.e., rotor speed, as the input. A selection–breakage approach is then used to create the particle size distribution (PSD). For each site, the model is trained with two datasets for the PSDs at different VSI rotor tip speeds. This allows the model to predict the product output for different rotor tip speeds beyond the experimental configurations. A dataset from 24 different sites in Sweden is used for training and validating the model to showcase the robustness of the model. The model presented in this paper has a low barrier for implementation suitable for trying different speeds at existing sites and can be used as a replacement to a manual testing approach.

ACS Style

Simon Grunditz; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Fit-for-Purpose VSI Modelling Framework for Process Simulation. Minerals 2020, 11, 40 .

AMA Style

Simon Grunditz, Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Fit-for-Purpose VSI Modelling Framework for Process Simulation. Minerals. 2020; 11 (1):40.

Chicago/Turabian Style

Simon Grunditz; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2020. "Fit-for-Purpose VSI Modelling Framework for Process Simulation." Minerals 11, no. 1: 40.

Journal article
Published: 14 December 2019 in Minerals
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Screening is a key operation in a crushing plant that ensures adequate product quality of aggregates in mineral processing. The screening process can be divided into the two sub-processes of stratification and passage. The stratification process is affected by the relative difference between various properties, such as particle shape, size distribution, and material density. The discrete element method (DEM) is a suitable method for analyzing the interactions between individual particles and between particles and a screen deck in a controlled environment. The main benefit of using the DEM for simulating the screening process is that this method enables the tracking of individual particles in the material flow, and all of the collisions between particles and between particles and boundaries. This paper presents how different particle densities and flowrates affect material stratification and, in turn, the screening performance. The results of this study show that higher density particles have a higher probability of passage because of their higher stratification rate, which increases the probability that a particle will contact the screen deck during the process.

ACS Style

Ali Davoodi; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Application of the Discrete Element Method to Study the Effects of Stream Characteristics on Screening Performance. Minerals 2019, 9, 788 .

AMA Style

Ali Davoodi, Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Application of the Discrete Element Method to Study the Effects of Stream Characteristics on Screening Performance. Minerals. 2019; 9 (12):788.

Chicago/Turabian Style

Ali Davoodi; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2019. "Application of the Discrete Element Method to Study the Effects of Stream Characteristics on Screening Performance." Minerals 9, no. 12: 788.

Journal article
Published: 17 October 2019 in Minerals Engineering
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Continuous process improvements are needed to maintain and run an industrial operation at a profitable state. An aggregates production plant consists of multiple process operations such as blasting, primary crushing, followed by secondary and tertiary crushing stages with an intermediate screening of products. Each of these processes can be operated with multiple objectives in mind of operators and plant managers. These objectives can be defined by varying terms like generating required throughput of the plant, maintaining equipment’s health, meeting customers’ demands, etc. The use of the term key performance indicators is recurrent in industry to formalise and represent these objectives of operation. Currently, the KPIs defined by the ISO 22400 standards are widespread for continuous improvements in the manufacturing industry and they are viewed as a support tool to measure improvements. The scope of this paper is to calculate relevant KPIs for an aggregates production plant using dynamic simulations. Further, the KPIs are implemented in a three-stage aggregate production plant using both real-time plant data and dynamic process simulation. The KPIs developed are useful for operators and plant managers to make decisions. The results show the relationship and dependencies of various equipment and process KPIs. The dynamic simulation has potential to be used as an exploration tool to identify the opportunities of improvement in aggregates processing using KPIs as a measure. The KPIs presented in the paper are based on ISO 22400 standard and have potential to be extended to similar processing operations such as coarse and fine comminution for minerals processing. Apart from the diagnostics application, the KPIs implemented in the dynamic simulation platform can be used to explore and optimize a crushing plant’s design and operations.

ACS Style

Kanishk Bhadani; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Development and implementation of key performance indicators for aggregate production using dynamic simulation. Minerals Engineering 2019, 145, 106065 .

AMA Style

Kanishk Bhadani, Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Development and implementation of key performance indicators for aggregate production using dynamic simulation. Minerals Engineering. 2019; 145 ():106065.

Chicago/Turabian Style

Kanishk Bhadani; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2019. "Development and implementation of key performance indicators for aggregate production using dynamic simulation." Minerals Engineering 145, no. : 106065.

Journal article
Published: 24 August 2018 in Minerals Engineering
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Optimization is a pivotal point in distinguishing the competitiveness of industries that are developing, designing and operating various products and processes. Mineral processing is an industry which operates various sub-processes and produces one or several products. The sub-processes involved are dynamic in nature and differ in the discipline of operation. These dynamic sub-processes are sequentially integrated forming a mineral processing system. Currently, the developed simulations for the mineral processing systems have the potential to be used to design, operate and control mineral processing plants to an increased extent, but need broader optimization strategies to integrate multiple sub-processes involved. The scope of this research is to demonstrate application of multi-disciplinary optimization (MDO) architectures into a mineral processing simulation. A simulation study consisting of two sub-processes of comminution and classification circuits to produce aggregate products is used to demonstrate the application of MDO architectures. The MDO architectures are compared based on problem formulation, computational resources required and validity of the results. The optimization results using MDO architectures can be used to illustrate trade-offs between different sub-processes within the considered scope. The application of MDO architectures can facilitate the linking mathematical models of various disciplines such as comminution, and liberation in mineral processing simulation.

ACS Style

Kanishk Bhadani; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Application of multi-disciplinary optimization architectures in mineral processing simulations. Minerals Engineering 2018, 128, 27 -35.

AMA Style

Kanishk Bhadani, Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Application of multi-disciplinary optimization architectures in mineral processing simulations. Minerals Engineering. 2018; 128 ():27-35.

Chicago/Turabian Style

Kanishk Bhadani; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2018. "Application of multi-disciplinary optimization architectures in mineral processing simulations." Minerals Engineering 128, no. : 27-35.

Proceedings
Published: 01 January 2018 in Proceedings
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The synthetic clay tennis court’s properties need to be examined and modified to converge towards the playing characteristics of the natural clay tennis court. The aim of this study was to investigate the responses of three distinct carpet-material combinations and evaluate how the materials’ alteration affected the results. The specimens were compressed uniaxially up to 2 kN at 400 N/s loading rate at varying number of cycles. Energy transformation, strain accumulation, step of strain accumulation and moduli of each surface combination were calculated. Results indicated that the measurements were affected by the loading history and that the carpet modification influenced mainly the energy transformation and the strain accumulation, while the material change affected additionally the moduli of the system. Conduction of the experiments enhanced understanding of the clay court’s response and could attribute to the initial modelling of the synthetic clay surface.

ACS Style

Panagiota Papadopoulou; Magnus Karlsteen; Magnus Gustafsson; Erik Hulthén. Investigation of Synthetic Clay Court’s Response under Cyclic Loading. Proceedings 2018, 2, 280 .

AMA Style

Panagiota Papadopoulou, Magnus Karlsteen, Magnus Gustafsson, Erik Hulthén. Investigation of Synthetic Clay Court’s Response under Cyclic Loading. Proceedings. 2018; 2 (6):280.

Chicago/Turabian Style

Panagiota Papadopoulou; Magnus Karlsteen; Magnus Gustafsson; Erik Hulthén. 2018. "Investigation of Synthetic Clay Court’s Response under Cyclic Loading." Proceedings 2, no. 6: 280.

Journal article
Published: 01 May 2017 in Minerals Engineering
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ACS Style

Marcus Johansson; Magnus Bengtsson; Magnus Evertsson; Erik Hulthén. A fundamental model of an industrial-scale jaw crusher. Minerals Engineering 2017, 105, 69 -78.

AMA Style

Marcus Johansson, Magnus Bengtsson, Magnus Evertsson, Erik Hulthén. A fundamental model of an industrial-scale jaw crusher. Minerals Engineering. 2017; 105 ():69-78.

Chicago/Turabian Style

Marcus Johansson; Magnus Bengtsson; Magnus Evertsson; Erik Hulthén. 2017. "A fundamental model of an industrial-scale jaw crusher." Minerals Engineering 105, no. : 69-78.

Journal article
Published: 01 April 2017 in Minerals Engineering
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There is an increasing demand to optimize performance and profit of comminution circuits. Research in this area has resulted in the development of numerous optimization tools, and recent research has shown that the quality aspects of the production have a great influence on the optimization results. The quality, cost, profit and capacity of a product are influenced by several parameters, and in order to control all of these parameters it is necessary to use some sort of optimization algorithm. In this paper, a novel approach to apply e.g. cost, revenue, capacity and quality in order to perform a multi objective optimization with the ability to handle dynamic variations of a comminution is presented. The problem with optimizations in general is that the objective function used for optimization is reduced in complexity in order to save computational time. In a comminution process performance varies with time and in order to perform a correct optimization the objective function used must be able to handle this type of dynamic behavior. The process has a given set of constraints that represents the conditions normal in these type of comminution 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. In this step a dynamic response model is described that will be able to address the difficulties with optimizing dynamic systems. The next step in the optimization is the definition of the multi-objective optimization formulation including constraints for the optimization. Evaluating the result of the optimization in combination with a strategy for relaxing constraint can show how to increase overall productivity and still reach certain product properties. The conclusions made in this work are that multi objective optimization is essential when optimizing a comminution circuit against multiple objectives.

ACS Style

Magnus Bengtsson; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Towards dynamical profit optimization of comminution circuits. Minerals Engineering 2017, 103-104, 14 -24.

AMA Style

Magnus Bengtsson, Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Towards dynamical profit optimization of comminution circuits. Minerals Engineering. 2017; 103-104 ():14-24.

Chicago/Turabian Style

Magnus Bengtsson; Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2017. "Towards dynamical profit optimization of comminution circuits." Minerals Engineering 103-104, no. : 14-24.

Journal article
Published: 01 April 2017 in Minerals Engineering
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ACS Style

Marcus Johansson; Johannes Quist; Magnus Evertsson; Erik Hulthén. Cone crusher performance evaluation using DEM simulations and laboratory experiments for model validation. Minerals Engineering 2017, 103-104, 93 -101.

AMA Style

Marcus Johansson, Johannes Quist, Magnus Evertsson, Erik Hulthén. Cone crusher performance evaluation using DEM simulations and laboratory experiments for model validation. Minerals Engineering. 2017; 103-104 ():93-101.

Chicago/Turabian Style

Marcus Johansson; Johannes Quist; Magnus Evertsson; Erik Hulthén. 2017. "Cone crusher performance evaluation using DEM simulations and laboratory experiments for model validation." Minerals Engineering 103-104, no. : 93-101.

Journal article
Published: 01 November 2016 in Minerals Engineering
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Crushing is a harsh process and production units are subjected to wear and failure over time which will reduce the overall performance of the plant. To achieve optimum process performance, both time dependant process dynamics and operating conditions should be taken into account. In this paper the aim is to simulate the process from a more operational perspective to evaluate process performance and process optimum for different operations. The objective is to model and simulate the discrete phenomena that can cause the process to alter performance and implement it with dynamic process simulations. An approach for combining discrete event simulations with time-dependent simulations for process evaluation and optimization is presented. The proposed approach demonstrates a systematic way to evaluate the process performance and locating optimum process configuration, for a given condition. The developed models can be used to optimize different aspects of the operation depending on the defined objective function and the system boundaries. Optimization of process throughput by manipulating configuration of both the grizzly and the crushers, as well as the time between calibrations has been illustrated in this paper. Adjusting the process continuously and calibrating it at the appropriate time can have major benefits when it comes to the process availability and utilization, increasing performance by 4.1–9.3% in these cases. Evaluation of process robustness and availability with regards to process specific factors and variation gave an indication of the process and unit performance under a long operating period. By combining discrete and dynamic simulation, a higher simulation fidelity can be achieved to provide a more operational perspective to the optimization and process analysis.

ACS Style

Gauti Asbjörnsson; Magnus Bengtsson; Erik Hulthén; Magnus Evertsson. Modelling of discrete downtime in continuous crushing operation. Minerals Engineering 2016, 98, 22 -29.

AMA Style

Gauti Asbjörnsson, Magnus Bengtsson, Erik Hulthén, Magnus Evertsson. Modelling of discrete downtime in continuous crushing operation. Minerals Engineering. 2016; 98 ():22-29.

Chicago/Turabian Style

Gauti Asbjörnsson; Magnus Bengtsson; Erik Hulthén; Magnus Evertsson. 2016. "Modelling of discrete downtime in continuous crushing operation." Minerals Engineering 98, no. : 22-29.

Journal article
Published: 01 May 2016 in Minerals Engineering
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Highlights•The screen model originally derived by Monica Soldinger has been modified to better model different aperture configurations.•The model has been validated against full scale measurements.•The model described is a double deck banana screen with 5 sections. AbstractScreens are an important production unit in crushing plants. The performance of the screen is essential to the performance of the crushing plant. In this paper a mechanistic model of a banana screen is described and a novel model for screen deck configuration is presented. The developed model can be used for optimization of a screen so that it has the best possible performance with respect to different feeding conditions, in order to obtain a desired separation. The simulation results were compared to full scale test data and the conclusions from this comparison is that the screen model needs further parameters to handle the necessary screen deck configuration. An initial static model was derived to explain how the screen deck configuration will affect the screen efficiency. The modification of the screen deck parameters resulted in a better correlation both regarding size distribution and predicted capacity.

ACS Style

Gauti Asbjörnsson; Magnus Bengtsson; Erik Hulthén; Magnus Evertsson. Model of banana screen for robust performance. Minerals Engineering 2016, 91, 66 -73.

AMA Style

Gauti Asbjörnsson, Magnus Bengtsson, Erik Hulthén, Magnus Evertsson. Model of banana screen for robust performance. Minerals Engineering. 2016; 91 ():66-73.

Chicago/Turabian Style

Gauti Asbjörnsson; Magnus Bengtsson; Erik Hulthén; Magnus Evertsson. 2016. "Model of banana screen for robust performance." Minerals Engineering 91, no. : 66-73.

Journal article
Published: 01 June 2015 in Minerals Engineering
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ACS Style

Magnus Bengtsson; Erik Hulthén; C. Magnus Evertsson. Size and shape simulation in a tertiary crushing stage, a multi objective perspective. Minerals Engineering 2015, 77, 72 -77.

AMA Style

Magnus Bengtsson, Erik Hulthén, C. Magnus Evertsson. Size and shape simulation in a tertiary crushing stage, a multi objective perspective. Minerals Engineering. 2015; 77 ():72-77.

Chicago/Turabian Style

Magnus Bengtsson; Erik Hulthén; C. Magnus Evertsson. 2015. "Size and shape simulation in a tertiary crushing stage, a multi objective perspective." Minerals Engineering 77, no. : 72-77.

Journal article
Published: 01 April 2013 in Minerals Engineering
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ACS Style

Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Modelling and simulation of dynamic crushing plant behavior with MATLAB/Simulink. Minerals Engineering 2013, 43-44, 112 -120.

AMA Style

Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Modelling and simulation of dynamic crushing plant behavior with MATLAB/Simulink. Minerals Engineering. 2013; 43-44 ():112-120.

Chicago/Turabian Style

Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2013. "Modelling and simulation of dynamic crushing plant behavior with MATLAB/Simulink." Minerals Engineering 43-44, no. : 112-120.

Conference paper
Published: 01 January 2013 in IFAC Proceedings Volumes
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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.

ACS Style

G. Asbjörnsson; E. Hulthén; Magnus Evertsson. An On-Line Training Simulator Built on Dynamic Simulations of Crushing Plants. IFAC Proceedings Volumes 2013, 46, 218 -223.

AMA Style

G. Asbjörnsson, E. Hulthén, Magnus Evertsson. An On-Line Training Simulator Built on Dynamic Simulations of Crushing Plants. IFAC Proceedings Volumes. 2013; 46 (16):218-223.

Chicago/Turabian Style

G. Asbjörnsson; E. Hulthén; Magnus Evertsson. 2013. "An On-Line Training Simulator Built on Dynamic Simulations of Crushing Plants." IFAC Proceedings Volumes 46, no. 16: 218-223.

Journal article
Published: 01 June 2012 in Minerals Engineering
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ACS Style

Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. Modelling and dynamic simulation of gradual performance deterioration of a crushing circuit – Including time dependence and wear. Minerals Engineering 2012, 33, 13 -19.

AMA Style

Gauti Asbjörnsson, Erik Hulthén, Magnus Evertsson. Modelling and dynamic simulation of gradual performance deterioration of a crushing circuit – Including time dependence and wear. Minerals Engineering. 2012; 33 ():13-19.

Chicago/Turabian Style

Gauti Asbjörnsson; Erik Hulthén; Magnus Evertsson. 2012. "Modelling and dynamic simulation of gradual performance deterioration of a crushing circuit – Including time dependence and wear." Minerals Engineering 33, no. : 13-19.

Journal article
Published: 23 May 2011 in Minerals Engineering
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Cone crushers are used in the mineral, mining, and aggregate industry for fragmentation of rock materials, minerals and ores. Systems used for controlling the Closed Side Setting (CSS) on cone crushers, and thereby the size reduction, are widely used to compensate for wear of the manganese crushing liners and to protect the machines from overloads. With a frequency converter also the eccentric speed in a cone crusher can be adjusted in real-time in addition to the CSS. The eccentric speed affects the dynamic interaction between the rock material and the crusher liners. Especially the number of compressions the material is exposed to is affected and also the local compression of the rock material is affected, thus the particle-size distribution of the product. Eccentric speed also affects crusher capacity. Real-time feedback data on the sellable product streams can be obtained by applying mass-flow sensors to the process. The adjustment of these two online parameters in real-time can result in an increased potential for production yield; however, a nontrivial optimization problem with a large solution space also arises. As the feed material also varies, the optimal setting for the parameters varies in time. Herein, we report the development of a monitoring and control system including a two variable online algorithm for the selection of the setpoint for eccentric speed with respect to the current CSS. The different product yields from the crushing plant were monitored by mass-flow meters and continuously evaluated by a fitness function. A model for the outcome of the crushing stage, with the two parameters eccentric speed and CSS, was fitted mathematically to the measurement data. However, since the process varies continuously, due to the wear of crushers and screens and feed material variations, the performance landscape is also continuously varying. Therefore, an Evolutionary Operation (EVOP) approach was adopted, wherein the variations are instead used to continuously find an operating point closest to the optimal. The developed algorithm was tested and evolved at a crushing plant for aggregates that produces around 400,000 tonnes aggregates per year. The algorithm was implemented in a computer that communicated with the frequency converter and retrieved data from ten mass-flow meters in the process. The operator was able to interact and supervise the system through a Human Machine Interface (HMI). The result is an algorithm that can determine the position and direction of a dynamic speed control to continuously improve the process-operation point. The magnitude of the improvement potential compared to a fixed speed operation is from 5% to 20%.

ACS Style

Erik Hulthén; C. Magnus Evertsson. Real-time algorithm for cone crusher control with two variables. Minerals Engineering 2011, 24, 987 -994.

AMA Style

Erik Hulthén, C. Magnus Evertsson. Real-time algorithm for cone crusher control with two variables. Minerals Engineering. 2011; 24 (9):987-994.

Chicago/Turabian Style

Erik Hulthén; C. Magnus Evertsson. 2011. "Real-time algorithm for cone crusher control with two variables." Minerals Engineering 24, no. 9: 987-994.

Journal article
Published: 01 February 2009 in Minerals Engineering
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Cone crushers are used in the mineral, mining, and aggregate industry for fragmentation of rock materials. Control systems for cone crusher settings are widely used for compensating for wear and protecting the machines from high pressure. However, these systems focus on the crusher and not the crushed products. By applying measurement devices on the process the crusher can be run optimally from the saleable products point of view (unlike most existing systems which only protect the machine) in each time. The measurement devices can be mass flow meters, e.g. conveyor belt scales. To analyze data from the process and convert them to a desired CSS value, an algorithm was developed. The developed algorithm is tested and evolved at a real crushing plant for aggregates. The algorithm was loaded into a computer which could communicate with the crusher control system, read data from three mass flow meters, and also interact with the operators. The computer was reachable over the Internet by the researchers at Chalmers and the algorithm was tuned and improved on-line. The result is an algorithm which was capable of providing CSS set-points to the automatic setting regulation system. The amount of saleable product from the crushing stage improved 3.5%, when not limited by the hydraulic pressure, compared to when a fixed closed side setting is used. The use of the algorithm automatically compensates for changes in the feed material and it also decreases the need for calibration of the underlying system.

ACS Style

Erik Hulthén; Magnus Evertsson. Algorithm for dynamic cone crusher control. Minerals Engineering 2009, 22, 296 -303.

AMA Style

Erik Hulthén, Magnus Evertsson. Algorithm for dynamic cone crusher control. Minerals Engineering. 2009; 22 (3):296-303.

Chicago/Turabian Style

Erik Hulthén; Magnus Evertsson. 2009. "Algorithm for dynamic cone crusher control." Minerals Engineering 22, no. 3: 296-303.