System Project Introduction

Upgrade the crusher to be intelligent, focusing on fineness control;

Using dynamic control algorithms, the crusher fineness is close to the optimal fineness value, improving the bulk density (top-charged coke oven). This creates conditions for maximizing coke production;

Machines replace manual labor, improving production efficiency, reducing energy consumption, improving safety production levels, and achieving automated and intelligent crusher maintenance;

Realize cloud management of the crusher operation.

Current Situation & Pain Points of Crusher Maintenance：

Difficult Maintenance: Crusher maintenance uses manual labor, the process is complex, and the technical requirements are high

Low Efficiency: Maintenance requires multiple people to cooperate, it is time-consuming, laborious, and inefficient

Difficult Fineness Control: Manual operation based on experience, unable to achieve real-time quantification and precision control, large fineness fluctuations

Low Technical Level: Operators generally have a low technical level, and there is a shortage of personnel

Information Island: The crusher is an information island in the coking plant

Optimal Fineness: Refers to the coal fineness value that can ensure the optimal balance between coke yield and quality. The optimal fineness values for top-charged coke ovens and tamped coke ovens are approximately 77% and 90% (≤3mm).

Fineness and Bulk Density/Output: Under the condition that other process conditions remain unchanged, for every 1% closer to the optimal fineness value, the bulk density/output increases by 1.5%. (Necessary but not sufficient condition)

Coke Quality Indicators: Control of the optimal fineness not only improves the bulk density of coal charging but also improves or maintains key quality indicators of coke, including: CSR (coke strength after reaction), CRI (coke reactivity index), M40 (shatter strength), and M10 (abrasion resistance), etc.

Intelligent Crusher System Goals：

Approaching the "Optimal Fineness Value": Reducing the fineness fluctuation range, so that coke production is close to the maximum value under the condition that other production and process links remain unchanged, which is equivalent to improving coke production.

Considering comprehensive production processes, production line status, and management levels, an increase in production of 0.5%~1.5% can be achieved in the coking plant.

Improve the intelligence of crusher maintenance production and improve maintenance efficiency

Improve safety production and equipment maintenance levels

Realize cloud management of the crusher

(Crusher Preparation Stage) Intelligent Start-up/Shutdown：

Start-up Self-Check: The intelligent system will adjust the impactor chamber distance according to the fineness requirements, incoming material parameters, and equipment wear and tear.

Shutdown Detection: After the equipment is shut down, the intelligent system will promptly perform impact plate movement and hammer head wear detection, preparing for the next shift’s work

(Crusher Production Stage) Intelligent Inspection and Control and Safe Production：

Intelligent Detection: The intelligent system automatically detects the operating status of the crusher, monitoring: temperature, vibration, current/voltage and other physical parameters without manual intervention

Intelligent Adjustment: The system, based on system control, will adjust the impactor chamber distance in real-time according to the production operating parameters to achieve dynamic adjustment of fineness

Early Warning/Alarm: Once the equipment operating parameters exceed the threshold, the system will automatically issue early warning and alarm signals, perform preset early warning actions, or shut down directly, and at the same time, transmit the early warning/alarm signals through the data interface to the coal preparation production line control system to complete the alarm process. The goal of safe production has been achieved

(Crusher Maintenance Stage) Intelligent Maintenance：

Electric Winding: During equipment maintenance, the system’s electric winding function reduces labor intensity while ensuring safe production requirements for winding

Automatic Detection of Hammer Head Wear: The system automatically detects the hammer head wear and quantifies the degree of wear, providing data support for crusher forward and reverse switching and replacing hammer heads and other accessories

Electric Adjustment of the Impact Plate: The system provides a manual electric adjustment interface for the impact plate. When adjusting the impact plate and hammer head, the required 3~4 person collaborative operation is reduced to 1~2 people