Dynamic modeling and simulation of cone crushing circuits

As a common practice, steady-state models are used for simulation and process dimensioning of crushing circuits. However, intended circuit performance is rarely achieved due to constantly fluctuating feed-material size and characteristics. This gap between theoretical and realized performance has the potential for process control.Little scientific attention has been paid to the analytic control system design of crushing circuits. The current lack of suitable dynamic process models for the task is direct evidence of this. Therefore, it is not surprising that currently existing control applications are biased towards heuristic, model-free, non-analytic approaches.This paper presents an effective way to produce dynamic process models from established steady-state models. The resulting simulator makes it possible to develop control methods that fully utilize the capacity potential of crushers and facilitates efforts for energy-efficient operation of crushing circuits.

► Dynamic simulation models for cone crushing circuit unit operations are proposed.
► Modeling problem is approached from the analytic control system design perspective.
► A method for dynamic expansion of existing steady-state models is presented.
► Crushing circuit is a delay-dominant process.