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Gyratory and Cone Crusher Optimisation

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Gyratory and Cone Crusher Optimisation

June 15, 2023 nflg 0 Comments

Crusher Optimisation Overview

Bear Rock Solutions, in association with Met Dynamics, has developed a sophisticated model of gyratory and cone crushers that can greatly aid the optimisation of process performance through the mechanical design of the crushers and liners.

The Kinematic Crusher Model (KCM) successfully meshes a mechanical description of the crushing machine with the breakage characteristics of the feed material. The KCM therefore allows the examination of not only process performance, but also the mechanical response of the crusher.


Based on the work of Bearman, Briggs and Evertsson, the model couples the crusher chamber geometry with equations of particle motion and a population balance breakage model.

The model is then able to predict:
product size distribution;
power consumption;
internal chamber conditions; and
on-set of packing and power overload.

for any given combination of:
mantle and concave liner geometry;
Closed Side Setting;
eccentric throw and speed; and feed rate, size distribution and material hardness.

The following improvements can be realised through informed selection of liners, crusher design and operating conditions:
Product quality, e.g. P80, size distribution
Liner replacement schedules
Energy usage and operating cost
Avoidance of potentially damaging conditions (power and / or pressure)

BRS and Met Dynamics are skilled in both crusher engineering and simulation, and can analyse given situations to determine the opportunities for improvement.

The model generates a variety of key process and mechanical diagnostic parameters for use in the analysis. In combination, these provide a unique view of the crusher application.

Some of the key model diagnostics include:
Definition of the chamber choke point;
Changes in bulk density due to size reduction and progression through the chamber;
Distribution of crushing power in the chamber; and Ability of the liners to accept, nip and break materials at points through the chamber.

Alongside the diagnostic parameters, the traditional descriptors of process performance are also key outputs.


The Kinematic Crusher Model for gyratory and cone crushers is available now for use in consulting projects through BRS and Met Dynamics. Crushing is an important element in the mining and quarrying industries and KCM offers an independent solution for crusher optimisation that can potentially yield improved performance, reduced downtime and more overall energy efficient circuits.


Dr. Ted Bearman is a mining professional with 22 years experience including crusher design, flow sheet optimisation and mechanical/process improvement of crushers. Ted’s PhD and his subsequent work are widely credited as being the catalyst for a new wave of crusher models. The major innovations in practical crusher modelling over the last 15 years have emanated from students who have studied under Ted, namely Dr CM Evertsson and Dr CA Briggs. In the new Kinematic Crusher Model (KCM) Dr. Bearman has revisited the topic from a fundamental perspective, and in collaboration with Scott Munro, has developed a model that provides genuine insights into the machine-rock interaction.

Scott Munro is an independent consultant who specialises in the simulation and modelling of mining and mineral processing systems. Scott has an innovative approach to simulation and has led the development of systems to address the interface between the various aspects of the total mining value chain. In addition, Scott has also been pivotal in the development of leading edge simulation work for ore specific process models. In his past roles Scott has held positions with Rio Tinto, CSIRO and Hatch.

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