Modeling and optimization of sand crushing plant using experimental design methodology

Abstract

PurposeThe purpose of this paper is to present results of an experimental program conducted on manufacturing process of crushed sand. The aim of the research is to propose an optimized approach which allows to fix, directly at the process stage, the rate of fines in the produced crushed sand.Design/methodology/approachIn the first step of the study, samples of crushed sand are collected in situ, at each adjustment of the identified operating parameters. They are then analyzed in laboratory to retrieve especially the fines contents for each adjustment. These adjustments are conducted for all possible combinations of the extremum operating conditions of the parameters. In the second step of the study, the experimental design technique is applied to study the influence of the different factors, and to model the interaction between them. An expression is obtained and subjected to statistical tests, and then it is confronted to other experimental measures.FindingsParameters influencing the fines rates are identified and their effects are analyzed. The domain of variation of three predominant parameters is defined allowing to conduct in situ experiments with minimal incidence on the manufacturing disturbance. A mathematical model is proposed to quantify the crushed sand fines by analytical expression that takes into account the interaction between influencing parameters.Practical implicationsThe conducted experiments provided new data that will help to enhance and to better set up the settings of the parameters influencing the rate of filler. The proposed expression constitutes a practical tool for the manufacturer to fix the operating parameters values that results in a desired target fines contents.Originality/valueModeling and optimization of the sand crushing plant, considered here as a case study, has not been attempted previously. The conducted experiments and the proposed mathematical model constitute an original work of this study.