Mineral Processing Plant Motor Speed Control for Energy Efficiency

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Solution Overview

Problem

Mineral material processing plants face inefficiencies in energy usage and capacity utilization, as they often operate at suboptimal power levels due to variations in material load and quality, leading to increased energy consumption and reduced operational hours.

Innovation Solution

A method and system for controlling mineral material processing plants that dynamically adjust the motor speed in response to changes in material load and quality, maintaining constant actuator speeds by adjusting conveyor speeds and hydraulic volume flow, using a control system that includes variable-capacity motors or pumps to optimize energy use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the motor runs at constant high speed to maintain crusher operating speed, then the crusher operates efficiently, but energy consumption increases when material load is low

Engineering Contradiction:

Improvecrusher operating speed stabilityVSAvoidmotor energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The motor speed is made dynamically adjustable rather than constant. The control system continuously monitors material load and adjusts motor running speed accordingly, allowing the system to adapt between high-speed operation during high load and reduced-speed operation during low load, thus resolving the contradiction between maintaining stable crusher operation and reducing energy consumption.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The motor speed parameter is changed based on material load conditions. By varying the motor running speed parameter in response to detected material quantity changes, the system maintains optimal crusher performance while avoiding excessive energy consumption during periods of low material availability.

Inventive Principle:

Principle #35Parameter changes

2Use of energy by moving object

If the motor speed is reduced to save energy, then energy consumption decreases, but the crusher operating speed varies and efficiency drops

Engineering Contradiction:

Improvemotor energy consumptionVSAvoidcrusher processing capacity

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

A feedback control mechanism is implemented where the control system continuously monitors material load conditions and adjusts motor speed accordingly. This feedback loop ensures that motor speed is reduced only when material load is sufficiently low, maintaining crusher efficiency during high-load periods while enabling energy savings during low-load periods, thus resolving the contradiction between energy consumption and processing capacity.

Inventive Principle:

Principle #23Feedback

3Productivity

If the processing plant operates continuously at full capacity, then productivity is maximized, but component lifespan decreases due to increased wear

Engineering Contradiction:

Improveprocessing plant operational hoursVSAvoidcomponent lifespan

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The system dynamically adjusts motor speed based on actual material load rather than operating continuously at full capacity. During periods of low material availability, the motor runs at reduced speed, which reduces mechanical stress and wear on components. This dynamic operation allows the plant to maintain high productivity during high-load periods while extending component lifespan during low-load periods.

Inventive Principle:

Principle #15Dynamics

4Use of energy by moving object

If the motor speed is adjusted frequently to match material load changes, then energy efficiency improves, but system complexity increases

Engineering Contradiction:

Improvemotor energy consumptionVSAvoidcontrol system complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The control system automatically monitors material load conditions and adjusts motor speed without requiring complex external control mechanisms. The system serves itself by using its own sensors and control logic to optimize motor operation based on real-time material availability, achieving energy efficiency through relatively simple self-contained control architecture.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10335800B2Method for controlling a mineral material processing plant and a mineral material processing plant

Publication Date: 2019.07.02 METSO OUTOTEC FINLAND OY

AI summary

A mineral material processing plant and a method for controlling thereof. The mineral material processing plant includes at least one motor, at least one actuator, a control system, an arrangement for holding the operating speed of the at least one actuator substantially unchanged. The control system is configured to control the processing plant in such a way that a change of amount and/or quality of material arriving to be processed is recognized and in response to the recognized change of amount and/or quality of the material arriving to be processed, the load of a motor is recognized, and in response to the recognized load of the motor, the running speed of the motor or motors of the mineral material processing plant is increased or decreased so that the operating speed of at least one actuator is held substantially unchanged.