Analysis Of Energy Consumption And Optimization Of Working Parameters Of Rotary Crusher Based On EDEM

The gyratory crusher is an important equipment in the coarse crushing stage of ore,which can realize the continuous crushing operation of ore materials through the cyclic rotational movement of the moving cone.Its stable working performance,large amount of crushed material and high productivity are widely used in crushing operations of mineral processing.At the same time,in the whole grinding process of ore materials,in order to achieve"extra crushing and less grinding,crushing as a substitute of grinding"to decrease the price of crushing operations,it is in particular vital to find out about the strength consumption in the crushing system of the gyratory crusher material.The motion nation of substances in the crushing chamber of the gyratory crusher is complicated and changeable,specifically the key working parameters have a higher influence on electricity consumption,and the three theoretical fashions of the normal crushing concept reflect consideration on much less of the true influencing elements when the ore is crushed,so the practicality is low.Taking Metso 60-110E gyratory crusher as the research object,his paper research the theoretical prediction mannequin of unique strength consumption per unit of gyratory crusher through EDEM’s simulation analysis of the material crushing process of gyratory crusher,and analyzes and concludes that reasonable changes to the key working parameters of the gyratory crusher such as dynamic cone speed n,moving cone bottom angleα,precession angleγ,and discharge particle size p₈₀can reduce he precise electricity consumption per unit of the crusher,and confirm the accuracy of the lookup outcomes in accordance to the genuine statistics of the ore crushing site of Metso 60-110E gyratory crusher.Firstly,this paper analyzes the energy consumption theory of gyratory crusher,and establishes the corresponding three-dimensional solid model of crusher.Using image processing technology,the grain size statistics of ore materials in the actual production process of Metso 60-110E gyratory crusher were made,three ore particle models of different sizes and shapes were established,and the ore specimens have been made the use of on-site ore uncooked materials,and the tensile compressive energy of the ore used to be calibrated in accordance to the uniaxial compression take a look at and Brazilian splitting take a look at of the ore specimen.The discrete thing simulation software program EDEM is used to simulate the fabric crushing method of the gyratory crusher,and in accordance to the evaluation of the movement nation and pressure of the ore fabric particles in the simulation process,the simulation evaluation of the fabric crushing of the gyratory crusher is close to the actual working conditions,and the results are reliable.Secondly,this paper formulates a four-factor three-level orthogonal test scheme on the key working parameters affecting the unit specific energy consumption of the gyratory crusher,and establishes different three-dimensional solid models of the gyratory crusher according to the different combinations of the values of each working parameter of the gyratory crusher in the test scheme,and simulates the material crushing process of the gyratory crusher.According to the test results,the response surface method was used to analyze the influence of the different values of dynamic cone speed n,moving cone bottom angleα,precession angleγ,and discharge particle size p₈₀ on the specific energy consumption of the gyratory crusher,and finally the theoretical prediction model of the specific energy consumption per unit of the gyratory crusher was established.Finally,by comparing and analyzing the actual production data of the material crushing site of Metso 60-110E gyratory crusher with the prediction consequences of the theoretical prediction mannequin of unit unique power consumption of the gyratory crusher installed in this paper,the real error between the proper price and the expected cost is solely 7.9%.Through the evaluation of variance of the electricity consumption prediction mannequin,it is concluded that the F value that can reflect the significance of the model is 7.89 and the P value is0.0002,both of which are within a reasonable range.Therefore,the theoretical prediction model of unit ratio energy consumption of gyratory crusher established in this paper is basically reliable,and its applicability is strong within the scope of test data.Based on the theoretical prediction model of the unit specific energy consumption of the gyratory crusher,the specific energy consumption per unit of the gyratory crusher is taken as the optimization goal,the crushing force of the crushing motor cone liner is the constraint,and dynamic cone speed n,moving cone bottom angleα,precession angleγ,and discharge particle size p₈₀ are the design variables,and the key working parameter values of the gyratory crusher are optimized.Through the analysis and comparison of several sets of simulation tests with the same crushing force before optimization,the unit specific energy consumption of the optimized gyratory crusher is reduced by about 5%,so the working performance of the optimized rotary crusher is greatly improved.