20 th International Conference on Renewable Energies and Power Quality (ICREPQ’22) Vigo (Spain), 27 th to 29 th July 2022 Renewable Energy and Power Quality Journal (RE&PQJ) ISSN 2172-038 X, Volume No.20, September 2022 Simulation of Energy Consumption in Jaw Crusher Using artificial intelligence models Khaled Ali. Abuhasel 1 1 Mechanical Engineering Department, College of Engineering, University of Bisha, Bisha, (Kingdom of Saudi Arabia) Phone/Fax number: +966554040092, e-mail: kabuhasel@ub.edu.sa Abstract. Crushing is an important operation in a variety of industrial applications since it requires a significant amount of energy to blast materials into certain sizes of shattered boulders. Because accurate predictions of the energy required to manage this process are rare in the literature, there have been few efforts to reduce power consumption at the crushing stage by using a jaw crusher, which is the most common type of crusher. The availability of precise power predictions, as well as the optimization of initial crushing processes, would provide useful tools for selecting the best crusher for a given application. The Adaptive Neuro-Fuzzy Interference System is used to predict the particular power consumption of a jaw crusher in this study (ANFIS). Apart from the power required for rock comminution, the analysis includes an optimization of the crushing process to lower the projected power. In comparison to real data, the results show that the model is successful in correctly estimating comminution power with an accuracy of more than 96%. The findings provide valuable information that can be applied to future studies. Key words. Neuro-Fuzzy, Energy consumption, ANFIS, Rock strength. 1. Introduction The size reduction of feed rocks is an important mechanical operation in the processing of raw materials in several industries such as mining and the cement industry. The rock blasting process is the most basic and first important stage in various industrial sectors, in which enormous rocks are broken and divided into tiny pieces before being sent to the processing plant. This procedure can be carried out using mechanical equipment, which are generally referred to as crushers. The primary crushers are capable of handling huge rocks of large size (typically around 1.5 m) to provide blasted rocks with size reduction ratio varying from 3 to 10 [1]. The maximum rock size fed to the crusher compared to the maximum rock size provided by the crusher is known as the rock size reduction ratio. The crushing process is a multi-stage dry process where each stage has small size reduction ratio within range from 3 to 6. Rock breakage is accomplished by crushing, impact, and abrasion corresponding to known modes of rock fracture; including compressive, tensile, and shear. The applied mode can be defined according to the rock mechanics and the load type. Rocks meet crushing (or compressive failure) where rocks of two distinct size ranges are obtained. In this mode, the coarse rocks are produced due to tensile failure, while the small size rocks result from compressive failure occurring at loading points or due to shear stress between projected rocks. In tensile failure mode (impact crushing), the rock possessing higher stress over stress needed to achieve fracture has great tendency to break rapidly producing smaller rock sizes and shapes. In the final mode; shear failure (attrition mode), the rocks are broken due to particle-particle interaction producing great part of fine size rocks. The later mode can occur when too fast feeding of a crusher is applied which is usually undesirable. Crushing in closed circuit operations produce more undesirable fine material than do open circuit operations. The crushing action comes from stresses applied to rock particles by moving parts of the machine. One of the most famous and old crushers is the jaw crusher. Jaw crushers are in practical usage for about 175 years. There are different jaw crushers that can be distinguished by the presence of two plates where crushed materials are fed between them. One of these plates is fixed while the other swings. Jaw crushers are classified according to the location of this pivoted swinging plate into Blake, Dodge, and Universal crushers. The Blake crusher is considered the most common one, in which the swinging plate is pivoted at the top [2]. This crusher can be realized in two forms as double toggle and single toggle. Due to its simplicity, lower cost, and its higher efficiency, the single toggle jaw crusher is the most realized form in new applications. Jaw crushers achieve size reduction mainly by compressing particles between relatively slow moving, inclined surfaces. The material being fed into the machine enters from above, where the crushing surfaces are furthest apart, and is crushed into smaller fragments as it descends into the narrowest zone of crushing and is finally discharged by gravity. The crushing surface in a jaw crusher consists of two rectangular plates, one fixed crushing face and an inclined mobile face, which moves a small distance back and forth from the fixed face. The major variables in jaw crushing are the angle of the jaws, rate of jaw movement, https://doi.org/10.24084/repqj20.220 67 RE&PQJ, Volume No.20, September 2022