Mineral processing plant

Abstract

The invention relates to a mineral processing plant for crushing mineral material or the like, using a crushing device and an internal combustion engine, wherein in a first mode of operation an internal combustion engine is mechanically coupled to the crushing device to drive the latter, wherein a generator is provided, which is mechanically coupled to an internal combustion engine to drive this generator, and wherein the generator is coupled to one or more auxiliary units to supply to supply electric power thereto.

In this context, provision is made for an electric motor to be provided separately from the generator, which electric motor is mechanically coupled to the crushing device in a second operating mode to drive the crushing device.

The invention further relates to a method for operating such a mineral processing plant. The mineral processing plant makes for an energy-efficient operation.

Claims

1-16. (canceled)

17. A mineral processing plant for crushing mineral material, comprising: a crusher; an internal combustion engine; an electric generator mechanically coupled to the internal combustion engine such that the electric generator may be driven by the internal combustion engine; one or more auxiliary units electrically connected to the electric generator such that the electric generator may provide electric power to the one or more auxiliary units; and an electric motor separate from the electric generator; wherein in a first mode of operation the internal combustion engine is mechanically coupled to the crusher to drive the crusher; and wherein in a second mode of operation the electric motor is mechanically coupled to the crusher to drive the crusher.

18. The mineral processing plant of claim 17, wherein: in the first mode of operation the electric motor is mechanically disconnected from the internal combustion engine and the electric generator by a clutch.

19. The mineral processing plant of claim 17, further comprising: a clutch configured to selectively couple the electric motor to the crusher; wherein in the first mode of operation the electric motor is disconnected from the crusher by the clutch; and wherein in the second mode of operation the electric motor is connected to the crusher by the clutch.

20. The mineral processing plant of claim 17, wherein: in a third mode of operation both the internal combustion engine and the electric motor are mechanically coupled to the crusher to drive the crusher.

21. The mineral processing plant of claim 20, further comprising: an accumulator for storing electrical energy; wherein in the first mode of operation the accumulator is electrically connected to the electric generator such that the accumulator is charged by the electric generator; and wherein in the third mode of operation the electric motor is supplied with electric energy from the accumulator and/or from an external power supply.

22. The mineral processing plant of claim 17, further comprising: a first clutch configured to selectively couple the internal combustion engine to the crusher; wherein in the first mode of operation the first clutch couples the internal combustion engine to the crusher; and wherein in the second mode of operation the first clutch disconnects the internal combustion engine from the crusher.

23. The mineral processing plant of claim 17, further comprising: a first transmission connecting the internal combustion engine to the crusher in the first mode of operation.

24. The mineral processing plant of claim 23, further comprising: a second transmission connecting the internal combustion engine to the generator.

25. The mineral processing plant of claim 23, wherein: the first transmission is integrated in a drivetrain between the internal combustion engine and the crusher and between the electric motor and the crusher.

26. The mineral processing plant of claim 25, further comprising: the first clutch is integrated in the drivetrain between the internal combustion engine and the first transmission; and a second clutch is integrated in the drivetrain between the electric motor and the first transmission.

27. The mineral processing plant of claim 17, further comprising: a machine chassis; one or more electric or electrohydraulic travel drives configured to move the machine chassis; and an accumulator for storing electrical energy; wherein at least one of the one or more travel drives is supplied with electric power from the generator and/or from an external power supply and/or from the accumulator.

28. The mineral processing plant of claim 27, further comprising: a power supply controller configured to receive electrical power from the generator and/or from the external power supply and/or from the accumulator, the power supply controller being further configured to supply electrical power to the one or more auxiliary units and/or to the electric motor and/or to the at least one of the one or more travel drives.

29. The mineral processing plant of claim 17, further comprising: a first transmission connecting the internal combustion engine to the crusher in the first mode of operation; a second transmission connecting the internal combustion engine to the generator; a hydraulic pump connected to and driven by the first or second transmission; and a hydraulic motor connected to the hydraulic pump by a hydraulic line, the hydraulic motor being connected to a fan to drive the fan for cooling of the internal combustion engine and/or the electric motor.

30. The mineral processing plant of claim 17, wherein: the internal combustion engine has a maximum continuous power output equal to 3 times P; the electric motor has a maximum rated power input equal to 2 times P plus or minus 30% of 2 times P; and the generator has a maximum rated power output equal to P plus or minus 30% of P.

31. The mineral processing plant of claim 17, further comprising: a first clutch configured to selectively couple the internal combustion engine to the crusher; a second clutch configured to selectively couple the electric motor to the crusher; wherein the first clutch and the second clutch are combined in one assembly as a double clutch.

32. The mineral processing plant of claim 31, wherein: the first and second clutches are fluid clutches, dog clutches, multi-disk clutches or free-wheel clutches.

33. The mineral processing plant of claim 17, wherein: in a start-up mode of operation with the crusher at a standstill, the internal combustion engine is started and brought up to an operating speed, and then power transmission from the internal combustion engine to the crusher is built up over a period of time.

34. The mineral processing plant of claim 17, wherein: in a start-up mode of operation with the crusher at a standstill, the crusher is first started up by the electric motor, and then the internal combustion engine is coupled to the crusher by a clutch.

35. A method of operating a mineral processing plant for crushing mineral material, the mineral processing plant including a crusher, an internal combustion engine, an electric generator mechanically coupled to the internal combustion engine, and an electric motor separate from the electric generator, the method comprising: in a first mode of operation mechanically coupling the internal combustion engine to the crusher and driving the crusher with the internal combustion engine; and in a second mode of operation mechanically coupling the electric motor to the crusher and driving the crusher with the electric motor.

36. The method of claim 35, further comprising: in a third mode of operation mechanically coupling both the internal combustion engine and the electric motor to the crusher and driving the crusher with both the internal combustion engine and the electric motor.

Description

[0044] FIG. 1 shows a simplified block diagram of a mineral processing plant, and

[0045] FIG. 2 shows a simplified schematic diagram of the structure of a mineral processing plant.

[0046] FIG. 1 shows a simplified block diagram of a mineral processing plant having a crushing device 13 and an internal combustion engine 10.

[0047] The crushing device 13 in this case is a jaw crusher, but it is also conceivable to use a different type of crusher, such as a rotary impact crusher, a gyratory crusher or a cone crusher. The internal combustion engine 10 may be a diesel engine or some other type of engine, such as a gasoline engine or a gas engine.

[0048] As can be seen in FIG. 1, the internal combustion engine 10 can be mechanically coupled to the crushing device 13. In this way, the internal combustion engine 10 can drive the crushing device 13.

[0049] In the illustrated exemplary embodiment, a first transmission 12 is provided in the drivetrain between the internal combustion engine 10 and the crushing device 13, which first transmission is coupled to the crushing device 13 by means of a drive 12.1. The first transmission 12 can be used to adjust torque and speed to the crushing device 13.

[0050] The drive 12.1 can be designed as a belt drive, for instance, which is connected to the output shaft of the transmission 12 and to the drive shaft of the crushing device 13.

[0051] Furthermore, a first clutch 11 is provided in the powertrain between the internal combustion engine 10 and the first transmission 12. The first clutch 11 establishes a mechanical connection between the output shaft of the internal combustion engine 10 and the input shaft of the transmission 12. However, the first clutch 11 can also be used to disconnect this mechanical connection.

[0052] Furthermore, the internal combustion engine 10 is mechanically coupled to a generator 15. In this way, the internal combustion engine 10 can drive the generator 15. The generator 15 can be used to convert mechanical output power of the internal combustion engine 10 into electric power.

[0053] A second transmission 14 is disposed between the internal combustion engine 10 and the generator 15. The output shaft of the internal combustion engine 10 is coupled to the input shaft of the second transmission 14, and the output shaft of the second transmission 14 is coupled to the input shaft of the generator 15. The second transmission 14 permits the speed at the drive shaft of the generator 15 to be adjusted. In this case, the second transmission 14 and the generator 15 are provided as independent assemblies. However, it is also conceivable to provide a joint unit, for instance in the form of a transmission-generator.

[0054] As can be further seen in FIG. 1, an electric motor 20 is also mechanically coupled to the crushing device 13. The electric motor 20 is connected to the first transmission 12 via a second clutch 19. Thus, the internal combustion engine 10 and/or the electric motor 20 can drive the crushing device 13 when a connection is established to the first transmission 12 via the first clutch 11 and/or the second clutch 19, respectively.

[0055] The first clutch 11 and the second clutch 19 can be of identical design and/or designed for the respective powers to be transmitted. It is also conceivable to use different types of clutches, wherein fluid clutches, dog clutches, multi-disk clutches and/or free-wheel clutches, for instance, are feasible. In addition, the first clutch 11 and the second clutch 19 can also be designed as a joint unit, preferably in the form of a double clutch.

[0056] The generator 15 may be electrically connected to a control device 18, as in the exemplary embodiment shown in FIG. 1. In this way, the electric power provided by the generator 15 is at least partially directed to the control device 18. The control device 18 is used to control and supply power to the electric motor 20 and is electrically connected thereto, as can be seen in FIG. 1.

[0057] Furthermore, provision may also be made for the control device 18 in the illustrated exemplary embodiment to control auxiliary units 17 of the mineral processing plant and/or to supply them with electric power.

[0058] Furthermore, a travel drive 16 of the mineral processing plant may be provided, which travel drive is electrically connected to the control device 18. The mineral processing plant may be equipped with a single travel drive 16. However, it is also conceivable to provide several travel drives 16 in order, for instance, to be able to control and drive individual axles, wheels or chain drives of the mineral processing plant separately. The travel drive(s) 16 is or are used to move the mineral processing equipment.

[0059] In this case, an external power supply 30 may also be provided to supply electric power to the mineral processing plant. A mains connection can be used for this purpose, for instance. The external power supply 30 is electrically connected to the control device 18.

[0060] The mineral processing system illustrated herein may further comprise an energy storage device 40 that may be electrically coupled to the control device 18, to the external power supply 30, to the generator 15, and/or to the electric motor 20.

[0061] The energy storage device 40 is preferably designed as an accumulator. The energy storage device 40 can be charged by the external power supply 30 or by the generator 15. The energy stored in the energy storage device 40 can then be used to drive the electric motor 20. In addition, the stored energy of the energy storage device 40 can be used to operate auxiliary units 17 of the mineral processing plant via the control device 18. The travel drive 16 can also be supplied from the energy storage device 40, such that local emission-free motion of the mineral processing plant is possible even without any external power supply 30.

[0062] The energy storage device 40 may be directly connected to the generator 15, the electric motor 20, and the external power supply 30. However, it is also conceivable to design the connection of the energy storage device 40 to all or some of these components indirectly, for instance via the control device 18.

[0063] The control device 18 may include comparatively simple and/or even complex electric and/or electronic circuits and elements. It is also conceivable to assign the entire control and/or regulation of the mineral processing plant including, for instance, all main and/or auxiliary units and/or mechanical components such as transmissions 12, 14 and/or clutches 11, 19 and/or the electric power supply by the external power supply 30 and/or the energy storage device 40 and/or the control circuit 41 to the control device 18. The control and/or regulation implemented by the control device 18 can be fully or partially automated, for instance by predefined processing programs. However, it is also conceivable that a machine operator performs the actuation and/or control and/or regulation of the components and/or aggregates of the mineral processing plant entirely or partly via the control device 18.

[0064] As can be further seen in FIG. 1, a hydraulic pump 50 is coupled to the first transmission 12. Mechanical power from the first transmission 12 can be supplied to the hydraulic pump 50 via the coupling. The hydraulic pump 50 is connected, for instance, to a hydraulic power unit 51 via a hydraulic line, such that the latter can be driven. The hydraulic power unit 51 can be a fan. In this way, the hydraulic unit 51 can be used to dissipate heat losses, for instance from the internal combustion engine 10 and/or the electric motor 20.

[0065] A hydraulic pump 50 may also be coupled to the second transmission 14. It supplies a further hydraulic unit 51. In particular, it may also be a fan. It is conceivable that this fan dissipates the heat losses of the generator 15.

[0066] It is also possible to provide a hydraulic pump 50 and a hydraulic unit 51 only on the first transmission 12 or only on the second transmission 14. It is also conceivable to provide only one hydraulic pump 50, by means of which one or more hydraulic units 51 are supplied.

[0067] FIG. 2 shows a schematic diagram of the mineral processing plant shown in FIG. 1.

[0068] As mentioned above, the mineral processing plant may comprise one or more auxiliary units 17.

[0069] As shown in FIG. 2, this can be an auxiliary hydraulic system with a hydraulic unit 17.5, a hydraulic valve 17.7 and an actuator 17.6. It is also conceivable that one or more auxiliary hydraulics are provided, each containing all or only some of the hydraulic components mentioned.

[0070] The auxiliary units 17 shown in FIG. 2 may furthermore include a conveyor belt 17.2, a conveyor chute 17.3 and/or a screen 17.4. Not all of these auxiliary units 17 have to be present. It is also conceivable to provide these auxiliary units 17 in different numbers at the mineral processing plant.

[0071] As FIG. 2 further shows, a control circuit 41 may be provided to interface with the energy storage device 40. In this case, it is designed as a separate unit. However, the use of an energy storage device 40 with an integrated control circuit 41 is also conceivable. In the exemplary embodiment shown, the energy storage device 40 is an accumulator. The control circuit 41 performs battery management, for instance, to control the charging and discharging operations of the energy storage device 40.

[0072] The drive 12.1 is designed as a revolving belt drive as shown in FIG. 2. However, other drive forms such as a chain drive or a drive shaft are also conceivable.

[0073] Likewise, the first transmission 12 and the second transmission 14 are provided as belt drives. However, both transmissions 12, 14 can also be of a different design, such as gear drives or hydraulic transmissions. In addition, a different type of transmission than the first transmission 12 may be provided for the second transmission 14.

[0074] As can be seen in FIG. 2, the generator 15 and the internal combustion engine 10 are directly connected to and coupled via the second transmission 14.

[0075] It can also be seen that the input 12.1 is directly connected to the output of the first transmission 12. The electric motor 20 and the internal combustion engine 10 can be coupled to the first transmission 12 via the first and via the second clutch 11, 19, respectively.

[0076] The crushing device 13 is designed as a jaw crusher unit having two crushing jaws. The crushing device 13 may also comprise a rotary impact crusher, a gyratory crusher, or a cone crusher.

[0077] The operation of the mineral processing plant shown is described below.

[0078] In a first operating mode, the internal combustion engine 10 is mechanically connected to and drives the crushing device 13. For this purpose, this connection is established by the first clutch 11 and the first transmission 12. In this way, the mechanical output power of the internal combustion engine 10 drives the crushing device 13 directly without having to accept conversion losses, for instance by converting mechanical power into electric power. In this way, an optimum efficiency factor can be achieved.

[0079] At the same time, the internal combustion engine 10 is connected to and drives the generator 15 via the second transmission 14. In so doing, the generator 15 converts the mechanical power transmitted thereto by the internal combustion engine 10 into electric power. The electric output power of the generator 15 is at least partially made available to the auxiliary units 17 via the control device 18. At the same time, provision may be made for at least a portion of the electric output power of the generator 15 to be fed into the energy storage device 40 for charging purposes.

[0080] In this first mode of operation, the electric motor 20 is mechanically disconnected from the crushing device 13. The second clutch 19 mechanically separates the electric motor 20 from the first transmission 12. Thus, the electric motor 20 does not contribute to driving the crushing device 13 and can be switched off to save energy. The mechanical separation from the drivetrain also means that the electric motor 20 does not have to be dragged along.

[0081] As a result of the internal combustion engine 10 driving the generator 15, electric power is converted from a portion of the mechanical drive power of the internal combustion engine 10, which can also be partially supplied to the travel drive 16 via the control device 18. Thus, in this first operating mode it is also possible to move the mineral processing plant during crushing operation. However, this is not always desirable, i.e., the mineral processing equipment may also remain stationary during this first mode of operation.

[0082] In a second mode of operation, the electric motor 20 is mechanically connected to the crushing device 13. The second clutch 19 mechanically connects the electric motor 20 to the first transmission 12. Thus, in this second mode of operation, the electric motor 20 accomplishes driving the crushing device 13.

[0083] The internal combustion engine 10 is mechanically disconnected from the crushing device 13 in this second operating mode. For this purpose, the separation is effected by the first clutch 11. At the same time, the internal combustion engine 10 is connected to the generator 15 via the second transmission 14 and can drive the former.

[0084] The mineral processing plant can be supplied with electric power via the external power supply 30. For instance, sufficient electric power can be provided via the external power supply 30 such that the internal combustion engine 10 can be switched off. In this way, the mineral processing plant can be operated locally without emissions. Since the first clutch 11 separates the internal combustion engine 10 from the drivetrain, no drag losses occur in this case. In this way a locally emission-free operation is rendered possible.

[0085] However, it is also possible for the internal combustion engine 10 to operate in this second mode of operation to drive the generator 15 for the purpose of obtaining electric power.

[0086] The electric output power of the generator 15 is then provided, at least in part, to the electric motor 20 via the control device 18 to drive the former. At the same time, at least a portion of the electric output power of the generator 15 can also be made available to auxiliary units 17 and/or fed into the energy storage device 40. Preferably, the energy storage device 40 can be charged when the mineral processing plant is dealing with a low load.

[0087] In this way, a stand-alone operation of the mineral processing plant independent of the external feed 30 can be implemented.

[0088] However, it is also conceivable that only part of the required electric power is provided via the external feed 30. In that case, the remaining demand for electric power can be covered by additionally operating the internal combustion engine 10 and driving the generator 15. Because the internal combustion engine 10 is mechanically disconnected from the crushing device 13 by the first clutch 11, the internal combustion engine 10 can be operated at partial load, for instance, in accordance with the need for additional electric power.

[0089] In so doing, in particular for the process of the mineral processing plant, the travel drive 16 can be supplied with electric power exclusively or in part via the internal combustion engine 10 and the generator 15. It is also conceivable to cover the electric power requirement of the travel drive 16 via the external power supply 30. However, the distances to be covered may be limited, for instance, by a limited available cable length.

[0090] It is also possible to charge the energy storage device 40 in the second operating mode. The electric energy required for this purpose can be provided by the external power supply 30 and/or, if the internal combustion engine 10 is operated, by the generator 15. Preferably, the energy storage device 40 is charged when the load on the mineral processing equipment is low.

[0091] In a third mode of operation, both the internal combustion engine 10 and the electric motor 20 are mechanically connected to the crushing device 13. The connection between the internal combustion engine 10 and the electric motor 20 is implemented via the first clutch 11 and via the second clutch 19. Thus, the mechanical output powers of both the internal combustion engine 10 and the electric motor 20 act on the crushing device 13 via the first transmission 12 and the drive 12.1.

[0092] In this regard, it is conceivable that the internal combustion engine 10 is designed to meet the average power requirements of the mineral processing plant. The electric motor 20 can absorb peak loads occurring during operation. In this way, the internal combustion engine 10 can be dimensioned smaller. In particular, in the third mode, the electric motor 20 may be powered by electric energy from the energy storage device 40. Alternatively or additionally, the external power supply 30 can be used for this purpose.

[0093] Because the internal combustion engine 10 is mechanically coupled to and drives the generator 15, electric power is also provided by the generator 15 in the third operating mode. It can be used to supply the auxiliary units 17 and/or the travel drive 16 and/or to charge the energy storage device 40.

[0094] In all of the above-mentioned operating modes, it is possible to cool the operated units, such as internal combustion engine 10 and/or electric motor 20, by means of the hydraulic units 51 connected to the respective transmissions 12, 14 via hydraulic pump 50.

[0095] The crushing device 13 requires a high torque to start up from standstill. This torque can be provided by the electric motor 20 when it is supplied with electric power via the external power supply 30 and/or the energy storage device 40 and/or the generator 15. In so doing, the internal combustion engine 10 is mechanically disconnected from the crushing device 13 by means of the first clutch 11. If desired, the internal combustion engine 10 can be mechanically coupled to the crushing device 13 after the crushing device 13 has started up.

[0096] It is also possible that in a start-up mode, while the crushing device 13 is stationary, the internal combustion engine 10 is started and brought to an operating speed. In so doing, the mechanical connection to the crushing device 13 is initially interrupted by the first clutch 11. The power flow between the internal combustion engine 10 and the crushing device 13 is then gradually established via the first clutch 11, similar to a motor vehicle with a manual transmission.