INVESTIGATION OF ROCK AGGREGATE QUALITY IMPROVEMENT THROUGH CHANGES IN CRUSHING CIRCUIT: A CASE STUDY ON VERTICAL SHAFT IMPACT CRUSHER

Year 2021, Volume: 9 Issue: 4, 1040 - 1050, 04.12.2021

Ekin Köken , Kerem Çimşir

https://doi.org/10.36306/konjes.871956

Cited By: 1

Abstract

The present study investigates the effects of rock crushing circuits on aggregate quality. For this purpose, a crushing – screening plant located in Vize (Kırklareli, Turkey) was considered. Based on the current operating conditions, the crushing – screening plant was modeled. The simulations revealed quantitative data on the production yield, efficiency of crushers, size reduction ratio. Concerning cone and vertical shaft impact crushers, rock aggregate quality was investigated for products with a particle size range of 33 – 63 mm. As a result of full-scale crushing tests, it was determined that the quality of rock aggregates is affected by the crushing circuit. Thanks to the several changes in crushing circuit, the Los Angeles abrasion value and flakiness index of the investigated rock aggregates were improved by 32% and 35%, respectively. The key points and details on the aggregate quality improvement processes were given in this study.

Keywords

Crushing – screening plant, Crushed stone, Aggregate quality, Cone crusher, Vertical shaft impact crusher

Agrega Kalitesi İyileştirmenin Kırma Döngüsü Değişimi İle Araştırılması: Dik Milli Kırıcı İçin Örnek Bir Çalışma

Abstract

Bu çalışma kaya kırma döngüsünün agrega kalitesi üzerinde olan etkilerini araştırmaktadır. Bu amaçla, Vize’de (Kırklareli, Türkiye) bulunan bir kırma – eleme tesisi dikkate alınmıştır. Mevcut çalışma koşulları dikkate alınarak, kırma – eleme tesisinin bilgisayar ortamında simülasyonu yapılmıştır. Simülasyonlar üretim miktarı, kırıcıların verimliliği ve boyut küçültme oranı gibi niceliksel verileri içermektedir. Konik ve dik milli kırıcılar dikkate alınarak, kaya agrega kalitesi 33 – 63 mm boyut grubundaki agregalar için araştırılmıştır. Büyük ölçekte gerçekleştirilen parçalanma deneylerinde, kaya agrega kalitesinin kırma döngüsünden etkilendiği belirlenmiştir. Kırma döngüsünde yapılan bazı değişimler ile, araştırılan agregaların Los Angeles aşınma değeri ve yassılık indeksi sırasıyla %32 ve %35 oranlarında iyileştirilmiştir. Bu çalışmada agrega kalitesi iyileştirme süreçlerine ilişkin ana hatlar ve detaylar verilmiştir.

Keywords

Kırma – eleme tesisi, Kırmataş, Agrega kalitesi, Konik kırıcı, Dik milli kırıcı

References

• Ajamu, S.O. and Ige, J.A., 2015, “Influence of coarse aggregate types and mixing method of concrete made from natural aggregate“, International Journal of Engineering and Technology, 5(7), 2049 – 3444.
• ASTM C136 / C136M ,2019, “Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates“, ASTM International
• ASTM D692/692M ,2015, “Standard specification for coarse aggregate for bituminous paving mixtures. “, ASTM International
• Bengtsson M. and Evertsson C.M., 2006, “Measuring characteristics of aggregate material from vertical shaft impact crushers“, Minerals Engineering. 19(15), 1479 – 1486.
• Bengtsson, M., 2009, “Quality-driven production of aggregates in crushing plants“, Dissertation, Chalmers University of Technology.
• Briggs, C., & Evertsson, C. M.., 1998, “Shape potential of rock.“, Minerals Engineering, 11(2), 125–132. BS EN 933–3, 2012, “Tests for geometrical properties of aggregates: Determination of particle shape, Flakiness index“, British Standards Institution, London
• BS EN 1097-2, 2010, “Tests for mechanical and physical properties of aggregates: methods for the determination of resistance to fragmentation. “, British Standards Institution, London
• BS EN 1097-6, 2013, “Tests for mechanical and physical properties of aggregates: determination of particle density and water absorption. “ British Standards Institution, London
• Chen Z. Wang G. Xue D. and Bi Q., 2020, “Simulation and optimization of gyratory crusher performance based on the discrete element method“, Powder Technology, 376, 93 – 103.
• Davoodi A., Asbjörnsson G., Hulthén E. and Evertsson M., 2019, “Application of the discrete element method to study the effects of stream characteristics on screening performance“, Minerals, 9(12): 788.
• DeDiemar R., 1990, “New concepts in jaw crusher technology“, Minerals Engineering, 3(1–2), 67 – 74.
• Djordjevic N., Shi F.N. and Morrison R.D., 2003, “Applying discrete element modelling to vertical and horizontal shaft impact crushers“, Minerals Engineering, 16(10), 983 – 991.
• Duthoit, V., 2000, “Crushing and grinding aggregates“, Chapter. 9, (Ed. Louis Primel and Claud Tourenq). Balkema, Rotterdam
• Eloranta, J., 1995, “Influence of crushing process variables on the product quality of crushed rock. “, Dissertation, Tampere University of Technology.
• Fladvad M. and Onnela T., 2020, “Influence of jaw crusher parameters on the quality of primary crushed aggregates“, Minerals Engineering. 151: 106338.
• Guimaraes, M. S., Valdes, J. R., Palomino, A. M., & Santamarina, J.C., 2007, “Aggregate production, fines generation during rock crushing“, International Journal Mineral Processing, 81(4), 237–247.
• Grunditz S., 2015, “Modeling and optimization of a vertical shaft impactor for production of artificial sand”, Master Thesis, Chalmers University of Technology
• Hafeez I., Juniad F., Kamal M.A. and Hussain J., 2016, “Influence of single- and two-stage aggregate manufacturing mechanisms on asphalt mixture performance”, Journal Materials in Civil Engineering 28(4), 04015180
• ISRM., 2007, “The complete ISRM suggested methods for rock characterization, testing, and monitoring”, 1974–2006. In: R. Ulusay, & J. A. Hudson (Eds.), Suggested methods prepared by the commission on testing methods. International Society of Rock Mechanics (ISRM), Ankara, Turkey.
• Kahraman S., Toraman O.Y., and Cayirli S., 2018, “Predicting the strength and brittleness of rocks from a crushability index”, Bulletin of Engineering Geology and the Environment, 77(4), 1639 – 1645.
• Kamani M. and Ajalloeian R., 2020, “The effect of rock crusher and rock type on the aggregate shape”, Construction and Building Materials, 230, 117016
• Kojovic, T., 1995, “Crushers: A quarry Australia special feature”, Quarry, 26–34.
• Korman, T., Bedekovic, G., Kujundzic, T., & Kuhinek, D., 2015, “Impact of physical and mechanical properties of rocks on energy consumption of jaw crusher”, Physicochemical Problems of Mineral Processing, 51(2): 461 – 475.
• Köken, E., and Özarslan, A., 2018, “New testing methodology for the quantification of rock crushability, compressive crushing value (CCV).”, International Journal of Mineral Metallurgy and Materials, 25(11), 1227–1236
• Köken E., 2020, “Evaluation of size reduction process for rock aggregates in cone crusher”, Bulletin of Engineering Geology and the Environment, 79, 4933 – 4946
• Köken E., Top S. and Özarslan A., 2020, “Assessment of rock aggregate quality through the analytic hierarchy process (AHP)”, Geotechnical and Geological Engineering 38, 5075 – 5096,
• Köken E. and Jili Q., 2020, “Comparison of secondary crushing operations through cone and horizontal shaft impact crushers”, In: 20th International Multidisciplinary Scientific Geoconference, SGEM 2020, pp 789 – 796
• Lee E, Evertsson C.M., 2011, “A comparative study between cone crushers and theoretically optimal crushing sequences”, Minerals.Engineering 24:188–194.
• Lee E., 2012, “Optimization of compressive crushing”, Dissertation, Chalmers University of Technology, Göteborg.
• Leiva, C. A., Arcos, K. V., Poblete, D. A., Serey, E. A., Torres, C. M., & Ghorbani, Y., 2018, “Design and evaluation of an expert system in a crushing plant.” Minerals, 8(10), 469.
• Li H. McDowell G.R. and Lowndes I.S., 2014, Discrete element modelling of a rock cone crusher”, Powder Technology 63, 151 – 158.
• Lindqvist M., 2008, “Energy considerations in compressive and impact crushing of rock”, Minerals Engineering, 21(9), 631 – 641.
• Metso., 2018, “Basics in mineral processing handbook.”, Metso Corporation.
• Nanthagopalan, P. and Santhanam, M., 2012, “An empirical approach for the optimisation of aggregate combinations for self-compacting concrete.”, Materials and Structures, 45, 1167 – 1179.
• Nduka D.O., Fabgenle O.I. Joshua O., Ogunde A.O. and Omuh I.O., 2018, “Comparative analysis of concrete strength utilizing quarry-crushed and locally sourced coarse aggregates”, International Journal of Mechanical Engineering Technology, IJMET, 9(1), 609 – 617
• Nikolov, S., 2004, “Modelling and simulation of particle breakage in impact crushers.”, International Journal of Mineral Processing, 74(10): 219–225.
• Quist J. and Evertsson C.M., 2016, “Cone crusher modelling and simulation using DEM”, Minerals Engineering, 85: 92 – 105.
• Rahimdel M.J. and Ataei M., 2014, “Application of analytical hierarchy process to selection of primary crusher”, International Journal of Mining Science and Technology, 24: 519 ‒ 523.
• Rajan B. and Singh D., 2017, “Understanding influence of crushers on shape characteristics of fine aggregates based on digital image and conventional techniques”, Construction and Building Materials, 150: 833 – 843.
• Rajan B. and Singh D., 2020, “Investigation on effects of different crushing stages on morphology of coarse and fine aggregates”, International Journal of Pavement Engineering 21(2), 177 ‒195.
• Svensson, A.; Steer, J.F., 1990, “New cone crusher technology and developments in comminution circuits.”, Minerals Engineering, 3, 83–103.
• Tavares L.M. and Da Silveria M.A.C.W., 2008, “Comparison of measures of rock crushability”, In Fine Particle Technology and Characterization, (Meftuni Yekeler Eds), ISBN: 978-81-308-0241-1
• TS 7043 EN 13450, 2004, “Aggregates for railway ballast”, Turkish Standards Institution, Ankara
• Ulsen, C., Tseng, E., Angulo, S. C., Landmann, M., Contessotto, R., Balbo, J. T., Kahn, H., 2019, “Concrete aggregate properties crushed by jaw and impact secondary crushing.”, Journal of Materials Research and Technology,8(1), 494–502.
• Xiao Y., Tutumluer E., Qian Y. and Siekmeier J.A., 2012, “Gradation effects influencing mechanical properties of aggregate base–granular subbase materials in Minnesota”, Transportation Research Record, 2267(1): 14 – 26