Case Studies

Three-Stage Limestone Crushing Plant Optimization

This case study presents the application of NiaFlow software in the development and optimization of a three-stage limestone crushing plant.

Project description

Introduction

This case study presents the application of NiaFlow software in the development and optimization of a three-stage limestone crushing plant. Each stage is set up in individual plants comprising primary, secondary, and tertiary crushing processes. The objective was to enhance the efficiency and flow of operations, utilizing closed crushing circuits for improved output quality.

Project Overview

Primary Crushing Plant: The process begins with the Run of Mine (ROM) stockpile feeding into a NIAGARA F-Class Scalper DSS 1400 x 4000, which directs the material to the Jaw Crusher. Post-primary crushing, the material is conveyed to Stockpile 2, ensuring continuity and stable material flow.
Secondary Crushing Plant: Material from Stockpile 2 is then transferred to the secondary plant, which features a NIAGARA T-Class 1500 x 5000 3D for further refinement. A Cone Crusher is used for secondary crushing, followed by material distribution via belt conveyers to either proceed to the tertiary plant or cycle back for reprocessing.
Tertiary Crushing Plant: The tertiary stage involves additional reduction by a second Cone Crusher, after which the material is allocated to various stockpiles (4, 5, and 6) through a series of belt conveyers. This final stage assures the material size reduction to meet the specified requirements.

Results

Throughout the process, NiaFlow software provides a comprehensive analysis of the material flow, with key metrics indicating the efficiency of each crushing stage. For instance, the primary plant achieves less than 20 mm particle size at a 95.6% success rate. In the secondary and tertiary stages, the software monitors the percentage of material under 5 mm and 10 mm respectively, with high efficiency rates over 98%, demonstrating the plant’s ability to maintain quality control throughout the processing sequence.
The use of NiaFlow in this project has demonstrated the software’s capability to streamline complex multi-stage crushing processes. By employing closed circuit operations, NiaFlow effectively managed and optimized the material flow, thereby enhancing the overall productivity and output quality of the limestone crushing plant.
The detailed visual representations provided by NiaFlow allowed for real-time adjustments and predictive analysis, ensuring that the operational parameters remained within the desired thresholds. This case study exemplifies the application of NiaFlow as a critical tool for engineers seeking to optimize mineral processing operations.

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