Optimization of crushing and screening circuit in quarry operation
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Date
2016-06
Authors
Mohd Amirol Ahmad Zamanhuri
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Abstract
This project was carried out to prove that the crushed rock material production process can be improved by means of computer simulation and optimization. This is due to an increasing demand to optimize yield and increase capacity of crushing plant. In this dissertation, a case study of a typical granite crushing plant in Juru is presented, with the goal to build up an ideal granite aggregates production circuit and producing an optimum condition for the crushing plant using computerized simulation method, while keeping the plant capacity and quality. Samples from the plant final crushing and screening equipment are analyzed using bulk sieving method and WipFrag fragmentation software to provide experimental data for optimization process using JKSimMet software that involves 3 main steps; simulation, model fitting and mass balancing. Simulation predicts the product stream distributions and capacity of the simulated circuit which then followed by model fitting that will fine-tune the simulation according to the plant and operating condition. The final step is mass balance that will help to access data efficiently and refines the experimental technique to improve the data quality. Depending on the optimization criteria, the result obtained can include maximized profit, increased product quality, and increased machine efficiency. At the end of this project, it is shown how the knowledge gained from the simulation and optimization can be used to improve the production of crushed rock material. The thesis presents a method to combine crushing plant simulation and optimization with quality and economic considerations in order to successfully study alternative configurations of the plant.