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    Production Costs Calculation Model in Crushing & Screening

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    Oktay Gülen
    This doctoral dissertation develops a product cost calculation model (PCCM) for calculating production costs in crushing and screening (C&S) plants used in mining and quarrying industries. The PCCM calculates costs using factors such as capital costs, operating costs, salaries, and auxiliary costs. It was tested on seven C&S plants and found conformity between calculated and actual costs of 0.9-1.2. The model can be used to calculate costs for existing plants or to estimate costs for future plant designs. Key applications are in mining and construction industries for processing rock and minerals.

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    Production Costs Calculation Model in Crushing & Screening

    Uploaded by

    Oktay Gülen
    50 views223 pages
    This doctoral dissertation develops a product cost calculation model (PCCM) for calculating production costs in crushing and screening (C&S) plants used in mining and quarrying industries. The PCCM calculates costs using factors such as capital costs, operating costs, salaries, and auxiliary costs. It was tested on seven C&S plants and found conformity between calculated and actual costs of 0.9-1.2. The model can be used to calculate costs for existing plants or to estimate costs for future plant designs. Key applications are in mining and construction industries for processing rock and minerals.

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    © © All Rights Reserved

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    This doctoral dissertation develops a product cost calculation model (PCCM) for calculating production costs in crushing and screening (C&S) plants used in mining and quarrying industries. The PCCM calculates costs using factors such as capital costs, operating costs, salaries, and auxiliary costs. It was tested on seven C&S plants and found conformity between calculated and actual costs of 0.9-1.2. The model can be used to calculate costs for existing plants or to estimate costs for future plant designs. Key applications are in mining and construction industries for processing rock and minerals.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    50 views223 pages

    Production Costs Calculation Model in Crushing & Screening

    Uploaded by

    Oktay Gülen
    This doctoral dissertation develops a product cost calculation model (PCCM) for calculating production costs in crushing and screening (C&S) plants used in mining and quarrying industries. The PCCM calculates costs using factors such as capital costs, operating costs, salaries, and auxiliary costs. It was tested on seven C&S plants and found conformity between calculated and actual costs of 0.9-1.2. The model can be used to calculate costs for existing plants or to estimate costs for future plant designs. Key applications are in mining and construction industries for processing rock and minerals.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 223

    Production Costs Calculation Model in Crushing and Screening

    Using a technical-economic approach tool for finding the optimal production costs when
    comparing technical and economical solutions
    Hedvall, Per

    2022

    Document Version:
    Publisher's PDF, also known as Version of record

    Link to publication

    Citation for published version (APA):


    Hedvall, P. (2022). Production Costs Calculation Model in Crushing and Screening: Using a technical-economic
    approach tool for finding the optimal production costs when comparing technical and economical solutions.
    [Doctoral Thesis (monograph), Production and Materials Engineering]. Department of Production and Materials
    Engineering, LTH, Lund University,.

    Total number of authors:


    1

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    LUNDUNI
    VERSI
    TY

    PO Box117
    22100L und
    +4646-2220000
    Production Costs Calculation
    Model in Crushing and Screening
    − Using a technical-economic approach tool for finding the optimal
    production costs when comparing technical and economical solutions

    PER HEDVALL | DIVISION OF PRODUCTION AND MATERIALS ENGINEERING


    FACULTY OF ENGINEERING | LUND UNIVERSITY
    NORDIC SWAN ECOLABEL 3041 0903
    Printed by Media-Tryck, Lund 2022
    9 789180 394055

    Division of Production and Materials


    Engineering, Faculty of Engineering

    ISBN 978-91-8039-405-5
    ISRN CODEN:LUTMDN/(TMMV-1074)/1-218/(2022)
    Production Costs Calculation Model in
    Crushing and Screening
    − Using a technical-economic approach tool
    for finding the optimal production costs
    when comparing technical and economical
    solutions

    Per Hedvall

    DOCTORAL DISSERTATION
    by due permission of the Faculty of Engineering, Lund University, Sweden.
    To be defended in lecture hall A:B, Sölvegatan 24, 223 62 Lund.
    Date 2022-11-18 and time 09:00
    Faculty opponent
    Professor Kerstin Johansen
    Department of Product Development, Production and Design, Jönköping
    University, Sweden
    Organization Document name:
    LUND UNIVERSITY Doctoral dissertation
    Faculty of Engineering
    Division of Production and Materials Date of issue: 2022-08-15
    Engineering
    Author(s): Per Hedvall Sponsoring organization: Sandvik SRP AB, Svedala
    Title and subtitle: Production Costs Calculation Model in Crushing and Screening

    The mining and quarrying industries represent a highly important sector of the Swedish economy. The mining
    industry operates globally, whereas the quarrying industry operates on a regional/local basis. Demands for metal
    and construction aggregates have increased over the last decade, and almost 80 billion tons of solid minerals and
    rocks are extracted from the earth’s crust each year. Construction aggregates are the largest part of this extraction.
    Most of the metals in the crust are in mineral form, with one or more elements in chemical compounds. To extract
    the metals, the rock must first be reduced to fine or very fine particles, so creating the right properties for mineral
    beneficiation and metal extraction.
    Construction aggregate is used as ballast in concrete and in asphalt or by itself in road building and other
    infrastructure, dams, protection, and padding. Construction aggregate ranges in sizes from large boulders to very
    fine sand, but normally the construction aggregate sizes are in the range of 1–100 mm. Railway aggregates are in
    the upper part of this range, aggregates used for asphalt and concrete in the middle, and sand in the lower part.
    Crushing and screening are among the common size reducers and size sorters in the mining and quarrying
    industries. The crushers are machines for breaking rocks or other minerals into smaller particles/fragments. The
    screens are the size-sorting machines for separating coarser particles from finer particles. Technical process
    simulation and equipment selection for crushing and screening (C&S) plants are well established for mining and
    quarrying plants.
    In this dissertation I develop a product cost calculation model (PCCM) that adds one more dimension to the area of
    process simulation, providing guidelines for calculating product costs within C&S plants and finding the process
    alternative with the lowest product cost for a C&S plant process application.
    The PCCM calculates the product costs using, process uptime costs, process downtime costs, salary costs and
    auxiliary costs. The process uptime and downtime costs include capital costs and dynamic process costs such as
    wear parts, spares, tools, and power consumption.
    The conformity, CF (calculated costs divided by actual costs) is in the range of 0.9–1.2 for the seven C&S plants
    tested. The application mining C&S plant gave the product cost allocation shown below:
    Costs Distribution (%)
    Capital 30–50
    Dynamic 30–40
    Salary 10–20
    Two examples demonstrate how the PCCM can be used:
    1. In an existing C&S plant to calculate the product costs.
    2. In a future C&S plant to calculate the production costs before the plant is built.
    Key words crushing, screening, C&S processes and plants, product cost calculations, mining, construction and
    quarrying.
    Classification system and/or index terms (if any)

    Supplementary bibliographical information Language: English

    ISSN and key title ISBN 978-91-8039-405-5

    Recipient’s notes Number of pages Price

    Security classification> Open

    I, the undersigned, being the copyright owner of the abstract of the above-mentioned dissertation, hereby grant to all
    reference sources permission to publish and disseminate the abstract of the above-mentioned dissertation.

    Signature Date 2022-08-15


    Production Costs Calculation Model
    in Crushing & Screening
    − Using a technical-economic approach tool
    for finding the optimal production costs
    when comparing technical and economical
    solutions

    Per Hedvall
    Cover photos by: Sandvik and Jan-Eric Ståhl

    Copyright Per Hedvall

    Faculty of Engineering
    Division of Production and Material Engineering

    ISBN 978-91-8039-405-5 (print)


    978-91-8039-406-2 (PDF)
    ISRN CODEN:LUTMDN/(TMMV-1074)/1-218/(2022)

    Printed in Sweden by Media-Tryck, Lund University, Lund 2022


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    1.Introduction
    The chapter begins with an account of the background of the research presented in
    the dissertation. Thereafter, it presents the conceptual approach taken, the
    objectives, the research questions posed, and the scope and the limitations of this
    project.

    1.1Background
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    1.2World production of solid minerals and rocks


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    Figure 1.1 World production of solid minerals, stones, and rocks [4, 16, 17, 18, 19, 20,
    21].

    1.3Mining industries
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    Figure 1.2 Overview of metal mining and metallurgy [4].

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    Figure 1.3 The metal process chain, from ore to finished product [4].

    
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    Figure 1.4 Overview of construction industries [4].

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    1.5 Crushing and screening (C&S)
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    1.5.1 Crushing and screening plants


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    Figure 1.5 Typical C&S plant from above, and a side view of the secondary station in the
    plant.

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    Figure 1.6 Typical stationary C&S plant (left) and a mobile C&S plant (right).

    1.5.2 Feeding and transportation


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    Figure 1.7 Vibrating feeder with dust encapsulation (left), and conveyors (right).

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    Figure 1.8 The two main rock-crushing principles [4].

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    Figure 1.9 Different types of compression crushers, gyratory, jaw, and cone [4].

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    1.5.4 Mechanical screening


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    Figure 1.10 The two main screening principles: right, screening through stratification,
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    Figure 1.11 Screen deck with rubber screening media with square holes.

    1.5.5 C&S circuits


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    Figure 1.12 Typical open (left) and closed (right) crushing circuit with explanations.

    
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    1.5.6 Plant configurations and product qualities


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    Table 1.1 Examples of raw materials and their properties that strongly affect crushing
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    Figure 1.13 Particle size distribution for a product (red) and a feed (blue) (left); and the
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    Table 1.3 Guideline for reduction ratio with required number of crushing stages [4].
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    1.8Scope and limitations


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    1.10 Outline of the thesis


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    2.Review of Product Cost Calculations
    This chapter reviews previous work in cost modeling related to crushing and
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    reference works are reported. However, little has been published in this specific
    field. The chapter results in a compilation of the most important published works.
    The compilation includes each model’s level of detail.

    2.1Introduction to product cost calculations


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    2.2General product/production cost calculations


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    2.2.1 General cost models for customized applications


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    2.3Absorption cost model


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    2.4Product cost calculations in C&S plants


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    Equation 2.10
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    Ǥ Equation 2.11
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    2.4.4 Dynamic profit optimization comminution circuit


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    Figure 2.2 Flowsheet of closed circuit.

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    2.4.5 Cost evaluation of producing different aggregate sizes


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    Figure 2.3 Cost allocation for Quarry 1 [47].

    
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    2.4.6 Crushing cost studies


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    Table 2.2 Investment costs, indirect investment including engineering, contractors, and
    contingency costs [48].

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    Figure 2.4 Examples of cost distribution in oil shale crushing [48].

    2.4.7 Improvement of efficiency in stone crushing


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    Table 2.3 Examples of equipment investment costs (INR, Indian rupee) in C&S plant [49].
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    2.4.8 Capital and operating costs of mineral processing plants


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    2.5Conclusions of the literature review


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    Table 2.6 Overview of the reviewed product cost calculation proposals.

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    3.Research Methodology
    This chapter explains the research approach taken and introduces the research
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    3.1Theory and methodology


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    3.1.1 Theories, models, and philosophies


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    Figure 3.1 Research paradigm in the field of production including the concept of digital
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    Figure 3.2 General overview of the complete work and the building of experience and the
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    Figure 3.3(a)Detail overview of the study approach and the thesis.

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    3.3Sampling, calculation, and balancing losses


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    ெ்೛౹ǡೕ

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    3.4Creating and developing the PCCM
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    3.5Validation of the developed PCCM


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    4.Basic PCCM Model for C&S
    This chapter provides explanations and equations related to C&S and presents the
    original model for production costs calculations for C&S as well as the associated
    research. The first application of the developed model is also presented in the form
    of a case study.
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    4.1Process comparison for cost calculations


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    Figure 4.1 Open and closed circuits in C&S.

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    4.2Open and closed crushing circuit analysis


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     and 
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    Table 4.1 Overview of manufacturing in C&S, casting, and machining [4, 10, 61].

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    ‫ݍ‬௉ ൌ  Equation 4.23
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    4.2.5 The ideal cost, k1Idel


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    4.2.6 Multiple stations and bottleneck identification


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    4.2.7 Cost calculation for one product in a single crush step


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    Figure 4.5 Production flow with recirculation for product P1.

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    Table 4.2 Selected basic data for the reported calculation example.

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    Figure 4.6 Example of the ideal cost kIdel as a function of the utilization URP.
    

    
    
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    Figure 4.8 The cost k per ton as a function of the flow (feed) L0 for different proportions of
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    4.3Dynamic cost simulation
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    4.3.1 The basics of dynamic simulation of current costs


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    4.3.2 Example of dynamic simulation of C&S


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    Figure 4.10 The distribution S (left) and the frequency function s (right) of the production
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    Figure 4.11 The distribution S (left) and the frequency function s (right) on the
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    Figure 4.12 The distribution S (left) and the frequency function s (right)on the
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    cost kkwh for three different levels of the occupancy rate URP.

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    studied variables and parameters according to cases a), b) and c).

    4.3.3 Results and discussion


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    Figure 4.14 Flowsheet of the gold ore C&S plant.

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    Figure 4.15 All cost term based on Weibull distribution functions together with the total
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    Figure 4.16 Frequency functions for all cost terms based on Weibull distributions together
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    Figure 4.17 Calculated and actual product costs [58].

    4.4Conclusions of the initial PCCM model


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    5.Model Refining for Several Products
    This chapter deals with further development of the model to a more comprehensive
    version that can handle several different products from one plant. In order to do
    this, it is necessary to be able to separate operating costs and allocate them to each
    product. The problem to be addressed is when several products pass through the
    same equipment and contribute to cost items such as wear parts, spare parts, and
    energy consumption. This second phase of the work was carried out after further
    information gathering and experience based on the previous chapter. An important
    part of this approach is the use of allocation keys when the C&S plant produces
    more than one end product.

    5.1Introduction to complex analysis


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    Figure 5.1 The Discrete model – all individual subprocesses in a C&S system.

    
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    5.2Improved cost model developments


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    5.2.1 One end product


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    Figure 5.3 A C&S plant with one end product, where the end product is extracted when
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    Figure 5.4 A typical C&S plant with two end products.

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    Table 5.1 Overview of type of allocation models.


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    5.2.3 Utilization of the C&S plant


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    5.2.4 Allocation keys


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    σ೔సభ ெ்ು೔

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    Figure 5.6 Crushing circuits, process chain with extraction of final products at different
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    Extracting products along the process chain


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    5.3An actual C&S plant with two end products


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    Figure 5.8 The iron ore C&S plant with each section, A, B, C, and D [64]. 

    5.3.1 Flow analysis and mass balances


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    Figure 5.11 The secondary station with mass balances (B).
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    Figure 5.12 The tertiary station with mass balances C.

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    Table 5.2 Flow production and investment: the iron ore C&S plant (Figure 5.8).
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    Table 5.3 The yearly production of the end products for the iron ore C&S plant.
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    5.3.2 Capital costs


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    Figure 5.14 Annuity factors for different technical lifetimes and different interest rates.

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    SURGXFWV

    5.3.3 Dynamic costs during operation and downtime


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    DQGSRZHUDUHDGGHG7KXVWKHG\QDPLFFRVWVRIXSWLPHDVIROORZV
    ௝ୀே Equation 5.6
    ݇௪௣ ௜ ൌ σ௝ୀଵ ೘ ‫ܭܣ‬௝ǡ௜ ‫݇ ڄ‬௪௣௝
    ௝ୀே೘

    ݇௦௣ ௜ ൌ ෍ ‫ܭܣ‬௝ǡ௜ ‫݇ ڄ‬௦௣௝ 


    ௝ୀଵ Equation 5.7
    ௝ୀே
    ݇௧௢ ௜ ൌ σ௝ୀଵ ೘ ‫ܭܣ‬௝ǡ௜ ‫݇ ڄ‬௧௢௝ 

    Equation 5.8
    
    DQG

    
    ௝ୀே Equation 5.9
    ݇௣௢௪ ௜ ൌ σ௝ୀଵ ೘ ‫ܭܣ‬௝ǡ௜ ‫ܶ ڄ‬௣௟௔௡ ‫݇ ڄ‬௘௡௝ ‫݇ ڄ‬௞௪౹ ‫ ڄ‬൫ͳ െ ‫ܦ‬௝ ൯ ‫ܷ ڄ‬ோ௉ 
    
    7DEOHVKRZVWKHDQQXDOFRVWIRU:36372DQGSRZHUIRUWKHPDLQPDFKLQHV
    Table 5.6 Examples of annual costs of WP, SP, TO, and power for two products, P1 and
    P2.

    6HF 0DFKLQH :33 :33 633 633 723 723 (13 (13

    WLRQ \  \  \  \  \  \  \  \ 

    $ &        

    % &        

    % 6        

    & &        

    & 6        

    ' 6        

    
    7KHRQO\G\QDPLFFRVWGXULQJGRZQWLPHLVWKHLGOHSRZHUXVHG NHQLGM 
    ௝ୀே
    ݇஼ௌௗ௬௡ǡ ௜ ൌ σ௝ୀଵ ೘ ‫ܭܣ‬௝ǡ௜ ‫ܶ ڄ‬௣௟௔௡ ‫݇ ڄ‬௘௡௜ௗǡ௝ ‫݇ ڄ‬௞௪౹ ‫ ڄ‬൫ͳ െ ‫ܦ‬௝ ൯ ‫ܷ ڄ‬ோ௉  Equation 5.10

    5.3.4 Salary costs


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    SURSRUWLRQDVWKHPDLQPDFKLQHVDVVKRZQLQ7DEOH
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    ODUJHUPDLQWHQDQFHDQGVHUYLFHV7KLVJLYHVDOPRVWZRUNHUVSHUVKLIWDURXQGWKH
    FORFNIRUWKHIXOO\HDU
    Table 5.7 Distribution of salary costs.
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    $ &)   
    % &6)   
    & &6)   
    ' 6$ %   

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    ே೘ǡ೔ ௡೚೛ ‫ڄ‬௞ವ ‫்ڄ‬೛೗ೌ೙
    ‫ܭ‬஽ǡ ௜ ൌ ‫ܭܣ‬௚ǡ௜ ‫ ڄ‬σ ‫ڄ‬ ೔స೙೛  Equation 5.11
    ே೘ǡೕ σ೔సబ ெ்ು೔

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    FRVWHTXDWLRQIRUHDFKHQGSURGXFWZLOOEH
    ‫ܭ‬௔௨௫ǡ ௜ ൌ ‫ܭܣ‬௚ǡ௜ ‫ ڄ‬σଵ௬௘௔௥ ݇௔௨௫  Equation 5.12

    5.3.5 Cost example of product P1 and P2


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    3   073< 86\

    3   073< 86\

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    3URGXFWLRQFRVWSHUVFWLRQ
     

    

    

    $ % & '

    Figure 5.15 The costs per section of the C&S iron ore plant.
    
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    ±WLPHVWKHQRUPDOOLIHWLPHDQGUHGXFHVWKH:3FRVWVWRWKHVDPHH[WHQW

    
    5.3.6 Cost conformity, CF
    7KH&)LVGHILQHGLQDSSHQGL[,DV
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    7KHYDOXHVRI&)DUHVKRZQLQ7DEOH
    Table 5.8 The conformity for P1, P2 and total in relation to available customer
    information.
    &)± 3 &)± 3 &)± 7RWDO
    § § §

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    SURGXFHG

    5.4The improved PCCM model


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    Production costs  
    Production costs during uptime
    Production costs during downtime
    Salary costs
    Auxiliary costs
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    ZLWKRWKHUDFWLYLWLHV HQYLURQPHQWDOFRVWVVLWHVHFXULW\FRVWVVLWHSUHSDUDWLRQFRVWV
    DQGUHVWRUDWLRQFRVWV

    5.4.1 Production costs during uptime


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    ௞బ೔ೠ೛೟ ା௞಴ು೏೤೙ǡು೔
    ݇஼௉ǡ ௉௜ ൌ
    ்೛೗ೌ೙ ‫ڄ‬ெ்೛೓ǡು೔
     Equation 5.13

    
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    ௝ୀே
    ݇௪௣ǡ ௉௜ ൌ σ௝ୀଵ ೘ ‫ܭܣ‬௝ǡ௜ ‫݇ ڄ‬௪௣௝  Equation 5.14
    ௝ୀே೘

    ݇௦௣ǡ ௉௜ ൌ ෍ ‫ܭܣ‬௝ǡ௜ ‫݇ ڄ‬௦௣௝ 


    ௝ୀଵ
    ௝ୀே೘
    Equation 5.15
    ݇௧௢ǡ௉௜ ൌ ෍ ‫ܭܣ‬௝ǡ௜ ‫݇ ڄ‬௧௢ǡ௝ 
    ௝ୀଵ
    ௝ୀே
    ݇௣௢௪ǡ௉௜ ൌ σ௝ୀଵ ೘ ‫ܭܣ‬௝ǡ௜ ‫ܶ ڄ‬௣௟௔௡ ‫݇ ڄ‬௘௡ǡ௝ ‫݇ ڄ‬௞௪௛ ‫ ڄ‬൫ͳ െ ‫ܦ‬௝ ൯ ‫ܷ ڄ‬ோ௉ 
    Equation 5.16

    Equation 5.17
    $QG
    ݇஼௉ௗ௬௡ǡ ௉௜ ൌ ݇௪௣௉௜ ൅ ݇௦௣௉௜ ൅ ݇௧௢௉௜ ൅ ݇௣௢௪௉௜  Equation 5.18
    

    5.4.2 Production costs during downtime


    7KHPDMRUSURGXFWLRQFRVWGXULQJGRZQWLPHN&63LLVWKHSDUWRIWKH($&&DFFRUGLQJ
    WRT6'DQG853
    ௞బ೔೏ೢ೟ା௞೛೚೏೟ೢ೔
    ݇஼ௌǡ ௉௜ ൌ
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     Equation 5.19
    ZKHUHNSRGWZLLVWKHFRVWGXULQJGRZQWLPHIRULGOHSRZHUXVHG

    5.4.3 Payroll and auxiliary costs


    7KHVDODU\FRVWN'3LLVFDOFXODWHGIRUSURGXFW3LDV
    ೟స೅೛೗ೌ೙
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    ்೛೗ೌ೙ ‫ڄ‬ெ்೛೓ǡು೔
     Equation 5.20

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    ்೛೗ೌ೙ ‫ڄ‬ெ்೛೓ǡು೔
     Equation 5.21
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    WKHDUHDXVHGE\WKHPDLQPDFKLQHVHTXLSPHQW

    
    7KHQWRWDOFRVWN3LIRUSURFHVVLQJSURGXFW3LSHUWRQFDQEHFDOFXODWHGDV 
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    5.5Conclusion
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    WRWKHHQGSURGXFWVDVGLVFXVVHGLQVHFWLRQ

    
    6.Model Verification
    In this chapter the PCCM calculation model is tested against five existing C&S
    plants to assess the conformity between the actual values provided and calculated
    values. Of these five cases, two are mining C&S plants and three are construction
    C&S plants. Thereafter, the PCCM is used on one simulated C&S circuit with two
    alternatives to find the alternative with the lowest special production costs. The
    production costs in earlier sections have been converted from local currency to US
    $, in order to compare the values given by customers and calculated or simulated
    values. This will make it possible to compare different applications from different
    places in the world.

     Prerequisites and assumptions


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    FXVWRPHURU& 6SODQWXVHUV

     C&S iron ore plant, product 0–16 mm


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    WKHKHPDWLWHW\SH7KHSODQWLVLQDUHJLRQWKDWKDVPRQVRRQUDLQVIRURQHPRQWK
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    @
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    Figure 6.1 The flowsheet for the 0–16 mm iron ore C&S plant (CSP 3).

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    GHSUHFLDWLRQFRVWVIROORZWKHWD[UXOHVLQHDFKFRXQWU\

    6.2.1 Actual identified production costs


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    Table 6.1 Product costs according to customer.
    ,WHP &RVW 86W  5HPDUNV
    (TXLSPHQW  6HHP\FRPPHQWVDERYH
    :36372  
    3RZHU  
    6DODU\  
    $X[LOLDU\  
    7RWDO  /RZGXHWRQRHTXLSPHQWFRVWV

    6.2.2 Calculated production costs in Appendix F3.


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    ±PPE\XVLQJWKHGHYHORSHG3&&0
    Table 6.2 Calculated product costs based on PCCM (Appendix F3).
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    :36372  
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    6DODU\  
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    &)D  
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    &)E  
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    SURFHVVLQJVWHSV

     C&S plant in copper mine, 1/4ȨȨ product


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    Figure 6.2 The flowsheet for the 0–¼ƍƍ copper ore C&S plant (CSP4).

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    DQGLQWHUPHGLDWHPDWHULDOIURPWKHVFUHHQV6$ %LVUHFLUFXODWHGWRFUXVKHUV&
    $ %7KHILQHVIURPVFUHHQ6$ %DUHWUDQVSRUWHGWRWKHHQGSURGXFWVLOR

    6.3.1 Given production costs for plant CSP 4


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    6DQGYLN¶VSODQWLQIRUPDWLRQGDWDEDVH>@
    Table 6.3 Actual product costs related to the copper ore C&S plant according to customer
    and Sandvik [25].
    ,WHP &RVW 86W  5HPDUNV
    (TXLSPHQW  
    '\QDPLFSURGXFWFRVWV  
    6DODU\  
    7RWDO  

    6.3.2 Calculated production costs


    &DOFXODWLRQVEDVHGRQWKH3&&0JLYHSURGXFWLRQFRVWVLQ7DEOH
    Table 6.4 Calculated product costs based on PCCM (Appendix F4).
    ,WHP &RVW 86W  5HPDUNV
    (TXLSPHQW  ,QWHUHVWUDWH 
    '\QDPLFSURGXFWFRVWV  
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    7KHFRQIRUPLW\HTXDWLRQJLYHV

    &)  

    
    ,QWKLVFDVHWKHGHYLDWLRQVDUHSULPDULO\GXHWRHTXLSPHQWFRVWVDQGDVVXPHGYDOXHV
    RIWKHLQWHUHVWUDWHS%\DVVXPLQJYDOXHVRISEHWZHHQDQGWKHFRQIRUPLW\
    YDULHVEHWZHHQDQG

     Mobile C&S plant with three products


    7KLVFDVHLQYHVWLJDWHVDPRELOH& 6SODQWZKLFKPRYHVDURXQGWRGLIIHUHQWVLWHV
    DQGMREVSURGXFLQJWKUHHHQGSURGXFWV,WLVGHVLJQHGIRUFDSDFLWLHVEHWZHHQWR
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    DQDVVXPHGDQQXDOSURGXFWLRQE\H[WHQGLQJWKHSUHVHQWVHWXSDQGUHTXLUHPHQWVWRD
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    Figure 6.3 The flowsheet of the mobile C&S plant (CSP 5).

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    E\DZKHHOORDGHU7KLVXQLWKDVDJUL]]O\IHHGHUDQGDMDZFUXVKHURQERDUG7KH
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    IHHGKRSSHURIWKHIHHGFRQYH\RURQWKHVHFRQGPRELOHFUXVKLQJXQLW$OOPDWHULDO
    LVFUXVKHGLQWKHVHFRQGDU\FUXVKHUDQGFRQYH\HGWRWKHIHHGKRSSHURIWKHPRELOH
    VFUHHQLQJXQLW7KHVFUHHQLQJXQLWKDVDWZRGHFNVFUHHQWKDWVHSDUDWHVWKHFRDUVH
    LQWHUPHGLDWHDQGILQHPDWHULDOV7KHVHSDUDWHGSURGXFWVDUHFRQYH\HGWRVWRFNSLOHV

    6.4.1 Given production costs for plant CSP 5.


    7DEOHGLVSOD\VWKHFRPSLOHGDQGVWUXFWXUHGGDWD7KHILJXUHVDUHEDVHGRQDFWXDO
    SURGXFWLRQ GDWD FRVWV FRPLQJ IURP ERWK WKH FXVWRPHU DQG 6DQGYLN¶V SODQW
    LQIRUPDWLRQGDWDEDVH>@
    Table 6.5 Actual product costs according to customer and Sandvik [25].
    &RVW
    ,WHP 5HPDUNV
    6(.W 
    (TXLSPHQW  7KHFXVWRPHUQRUPDOO\VHOOVKLVPRELOHXQLWV
    DEURDGDIWHUDSSUR[LPDWHO\ILYH\HDUV¶

    
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    LQYROYHG
    $X[LOLDU\ QD 
    7RWDO  ([FOXGLQJVDODU\DQGDX[LOLDU\FRVWV

    6.4.2 Calculated production costs


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    H[WUDFWHGIURPWKHODVWVWDJHRIWKHSODQW$OORFDWLRQNH\VZHUHXVHGDFFRUGLQJWR
    WKHSURSRUWLRQRIWKHILQDOSURGXFWVSURGXFHG
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    FRVWVWKHFRQIRUPLW\FDQEHFDOFXODWHGDV

    &)  


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    FRVWLVLQWKHUDQJHRIRIWKHWRWDOSURGXFWLRQFRVWZKLFKLVDVXEVWDQWLDOSDUW
    VHH $SSHQGL[ ) 6DODU\ FRVWV VKRXOG DOZD\V EH LQFOXGHG WR REWDLQ VXIILFLHQW
    DFFXUDF\LQGHWHUPLQLQJRUFDOFXODWLQJWRWDOSURGXFWLRQFRVWV%XWLQWKLVFDVHWKH
    6DODU\DQGWKH$X[LOLDU\FRVWVZHUHQRWHGRXWE\WKHFXVWRPHU
    )RUWKLVSODQWWKH3&&0RYHUHVWLPDWHVWKHG\QDPLFSURGXFWLRQFRVWVFRPSDUHGWR
    WKHFRVWJLYHQE\WKHFXVWRPHUDQG6DQGYLN¶VSODQWLQIRUPDWLRQGDWDEDVH>@
    
    Table 6.6 Calculated product costs based on PCCM.
    ,WHP &RVW 6(.W 5HPDUNV
    (TXLSPHQW  $VVXPLQJHTXLSPHQWVROGDIWHUILYH\HDUVUHFRXSV
    ,QWHUHVWUDWHRI 
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     ([FOXGLQJDX[LOLDU\FRVWV
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    EHWZHHQWKHDFWXDOFRVWVDQGWKHHVWLPDWHGFRVWV

    
     C&S plant 500 MTPH with six products
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    @7KHSURGXFWLRQGXULQJWKH\HDUGHSHQGVRQPDUNHWDFWLYLW\
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    TXDUU\ILQHVWKDWDUHGLUHFWO\UHPRYHGDV³VDQG´IRUSULYDWHXVHUVFXVWRPHUV7KLV
    ³VDQG´LVRIORZTXDOLW\DQGFDQQRWEHXSJUDGHG3URGXFW3LVUDLOZD\DJJUHJDWHV
    ZLWK KLJK VKDSH UHTXLUHPHQWV 7KH UHPDLQLQJ SURGXFWV 3 ± 3 DUH XVHG DV
    FRQVWUXFWLRQDJJUHJDWHVIRUFRQFUHWHRUDVSKDOW
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    Figure 6.4 The flowsheet of the fixed C&S plant (CSP 6).

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    7KHEODVWHGURFNLVVHSDUDWHGLQWRFRDUVHDQGILQHVE\WKHJUL]]O\VFUHHQGHFN7KH
    ILQHVDUHFRQYH\HGWRDVFUHHQ6WKDWUHPRYHVWKHTXDUU\ILQHVDQGLQWHUPHGLDWH
    PDWHULDO4XDUU\ILQHVDUHFRQYH\HGWRDVWRFNSLOHDVSURGXFW37KHFRDUVHPDWHULDO
    IURPWKHJUL]]O\VFUHHQGHFNLVFUXVKHGLQWKHFUXVKHU&7KLVFUXVKHGSURGXFWLV
    DGGHGWRWKHLQWHUPHGLDWHPDWHULDOIURP6DQGFRQYH\HGWRDVXUJHSLOHZLWKWXQQHO
    IHHGHU)URPWKHVXUJHSLOHWKHPDWHULDOLVWUDQVSRUWHGFRQYH\RUWRDVXUJHELQZLWK
    IHHGHUDKHDGRIWKHFUXVKHU&&UXQVLQFORVHGFLUFXLWZLWKDIRXUGHFNVFUHHQ
    67KHFRDUVHPDWHULDOIURPGHFNLVUHFUXVKHGLQ&7KHPDWHULDOIURPGHFN
    LV FRQYH\HG WR D VWRFNSLOH DV SURGXFW 3 7KH LQWHUPHGLDWH PDWHULDO IURP 6 LV
    FRQYH\HGWRDVXUJHELQZLWKIHHGHUDKHDGRIFUXVKHU&7KHILQHVIURP6DUH

    
    WUDQVSRUWHGGLUHFWO\WRWKHVWRFNSLOHIRUSURGXFW3&UXQVLQFORVHGFLUFXLWZLWKD
    IRXUGHFNVFUHHQ67KHFRDUVHPDWHULDOIURPGHFNLVUHFUXVKHGLQ&$OOWKH
    RWKHUPDWHULDOVIURPWKH6DUHFRQYH\HGWRWKHLURZQVWRFNSLOHDVSURGXFWV33
    DQG37KHILQHVIURP6DUHFRQYH\HGWRWKHVDPHVWRFNSLOHDVWKHILQHVIURP6
    SURGXFW3

    6.5.1 Given production costs for plant CSP 5


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    SURGXFWLRQGDWDFRVWVFRPLQJPDLQO\IURPWKHFXVWRPHUDQGDOVRIURP6DQGYLN¶V
    SODQWLQIRUPDWLRQGDWDEDVH>@
    Table 6.7 Actual product costs according to customer and Sandvik [25].

    ,WHP &RVW ¼WRQ  5HPDUNV


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    6DODU\  
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    SURGXFWLRQWRGHWHUPLQHWKHFRVWSHUWRQSURGXFHG

    6.5.2 Calculated production costs


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    FDVH SURGXFWV ZLOO EH H[WUDFWHG IURP WKH GLIIHUHQW & 6 VWDJHV RI WKH SODQW XVLQJ
    DSSURSULDWHDOORFDWLRQNH\V
    Table 6.8 Calculated product costs based on PCCM (Appendix F6).
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    (TXLSPHQW  ,QWHUHVWUDWH 
    '\QDPLFSURGXFWFRVWV  
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    7KHVHOHFWLRQRIFRPHVIURPLQWKHFRXQWU\ZKHUHWKH& 6SODQWLVORFDWHG>@

    7KHFRQIRUPLW\EHWZHHQDFWXDOFRVWVDQG3&&0EDVHGFRVWVFDQEHFDOFXODWHGDV

    &)  

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    SULPDULO\WRHTXLSPHQWFRVWV

    
     C&S plant 200 MTPH with four products
    7KLV & 6 SODQW LV LQ 6RXWK $VLD SURGXFLQJ IRXU FRQVWUXFWLRQ DJJUHJDWH SURGXFWV
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    KZRUNLQJGD\7KH& 6SODQWSURFHVVIORZVKHHWLVVKRZQLQ)LJXUH

    
    Figure 6.5 The flowsheet of the C&S plant (CSP 7).

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    7KHURFNLVIHGLQWRWKHJUL]]O\IHHGKRSSHU7KHJUL]]O\IHHGHUKDVWZRGHFNVWR
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    RYHU7KHILQHVWKDWIDOOWKURXJKWKHJUL]]O\DUHWKHQVHSDUDWHGLQWRWZRSURGXFWV
    LQWHUPHGLDWHDQGTXDUU\ILQHVRQWKHVHFRQGGHFNRIWKHJUL]]O\IHHGHU7KHFRDUVH
    PDWHULDOIURPWKHJUL]]O\GHFNLVFUXVKHGLQFUXVKHU&7KHLQWHUPHGLDWHPDWHULDO
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    VFUHHQ67KHFRDUVHPDWHULDOIURPGHFNQXPEHUWZRLVFRQYH\HGWRDVWRFNSLOHDV
    SURGXFW37KHPDWHULDOWKDWSDVVHVRYHUGHFNWKUHHLVFRQYH\HGWRDVWRFNSLOHDV
    SURGXFW 3 7KH PDWHULDO WKDW SDVVHV WKURXJK GHFN QXPEHU  LV FRQYH\HG WR D
    VWRFNSLOHDVSURGXFW3

    6.6.1 Given production costs for plant CSP 7


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    FXVWRPHUDQGWHVWV6RPHDGGLWLRQDOLQIRUPDWLRQKDVEHHQGUDZQIURP>@
    Table 6.9 Actual product costs according to customer and Sandvik [25].
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    (TXLSPHQW  (VWLPDWHGDQGFDOFXODWHGE\LQIRUPDWLRQIURPFXVWRPHU
    '\QDPLFSURGXFWFRVWV  (VWLPDWHGDQGFDOFXODWHGE\LQIRUPDWLRQIURPFXVWRPHU
    6DODU\  (VWLPDWHGDQGFDOFXODWHGE\LQIRUPDWLRQIURPFXVWRPHU
    7RWDO  ([FOXGLQJDX[LOLDU\FRVWV

    6.6.2 Calculated production costs


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    H[WUDFWHGIURPWKHGLIIHUHQW& 6VWDJHVRIWKHSODQWXVLQJGLIIHUHQWDOORFDWLRQNH\V
    Table 6.10 Calculated product costs based on PCCM (Appendix F7).
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    (TXLSPHQW  ,QWHUHVWUDWH 
    '\QDPLFSURGXFWFRVWV  
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    7KHVHOHFWLRQRIFRPHVIURPLQWKHFRXQWU\ZKHUHWKH& 6SODQWLVORFDWHG>@

    ,QWKLVFDVHWKHFRQIRUPLW\FRXOGEHFDOFXODWHGDV

    &)  

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    DWWULEXWHGSULPDULO\WRHTXLSPHQWFRVWV
    $VWKHDFWXDOSURGXFWLRQFRVWVZHUHHVWLPDWHGXVLQJLQIRUPDWLRQIURPWKHFXVWRPHU
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    $FFRUGLQJO\QRWWRRPDQ\FRQFOXVLRQVVKRXOGEHGUDZQUHJDUGLQJSURGXFWLRQFRVWV
    IURPWKLV& 6SODQW

    
     Applications related to selection of C&S plant
    )LQDOO\ WKLV FKDSWHU VKRZV DQ H[DPSOH RI D VLPXODWHG & 6 SODQW ZLWK WZR
    DOWHUQDWLYHVZKHUH3&&0LVXVHGWRGHWHUPLQHZKLFKSURFHVVDOWHUQDWLYHJLYHVWKH
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    FUXVKHUVDQGWKHIHHGHUV7KHWZRIORZVKHHWVDUHVKRZQLQ)LJXUH

     
    Figure 6.6 The two flowsheets for alternative A and B (CSP 8).

    7KHSUHFUXVKHGRUHLVIHGLQWRWKHVXUJHELQ V ZLWKIHHGHU V 7KHIHHGHU V IHHG


    WKHFUXVKHU V WKDWUXQLQFORVHGFLUFXLWZLWKDRQHGHFNYLEUDWLQJVFUHHQ7KHFRDUVH
    PDWHULDOIURPWKHVFUHHQLVIHGEDFNWREHUHFUXVKHGZKLOHWKHILQHVDUHWUDQVSRUWHG
    WRWKHSURGXFWVLOR

    6.7.1 Production costs for alternatives A and B, special cost


    $OWHUQDWLYH%ZLWKRQHODUJHUFUXVKHULVDOLWWOHPRUHFRVWHIIHFWLYHWKDQDOWHUQDWLYH
    $ ZLWK WZR VPDOOHU FUXVKHUV $Q DQQXDO VDYLQJ RI DSSUR[LPDWHO\ 86' LV

    
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    UXQQLQJFUXVKHUVDVVKRZQLQ7DEOH
    Table 6.10 Calculated special product costs for alternative A and B.
    3URGXFW&RVW W  3URGXFW&RVW W 5HPDUNV
    ,WHP
    $OWHUQDWLYH$ $OWHUQDWLYH%
    (TXLSPHQW   ,QWHUHVWUDWH 
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    DQGLVYDOLGIRUWKHDSSOLFDWLRQ\HDU>@

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    FRVWVIRUWKHDOWHUQDWLYHVZHUHXVHGLQWKHHYDOXDWLRQWRILQGWKHDOWHUQDWLYHZLWKWKH
    ORZHVWSURGXFWFRVWV

     Conclusions from the case studies conducted


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    DQGFDOFXODWHGRUPHDVXUHGLQSXWSDUDPHWHUV7KLVUHVXOWDOVRVKRZVKRZLPSRUWDQW
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    7.Discussion and Conclusions
    This chapter discusses the results achieved by using the PCCM. Conclusions are
    drawn, and then the two research questions are answered.

     Development
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    VHOHFWHGWRDFKLHYHSURGXFWLRQ

    7.4.1 General conclusion for RQ1


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    PHWKRGVDYDLODEOHWRGD\DVVKRZQLQ7DEOH
    Table 7.4 The features incorporated in the PCCM.
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    3HUVRQQHOFRVWV ; (QYLURQPHQWDOFRVWV ; 
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    06FRVWV ;  7RWDO3URGXFWLRQFRVWV ;
    3RZHUFRVWV ;   SDUWRIWKHDX[LOLDU\FRVWV

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    SURGXFWLRQFRVWV7DEOHVKRZVWKHIHDWXUHVLQWKHSDSHUVUHYLHZHGZLWKDQ;

    

    
    Table 7.5 Description of the level of detail of input cost items in reported cost models for
    C&S plants (from section 7.1).
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    5DZ0DWHULDOFRVWV ;         
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    DQVZHUV54

    7.4.2 General conclusions related to RQ2A – Open circuit


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    Figure 7.2 Open C&S circuit.

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    7.4.3 General conclusion for RQ2B - Closed crushing circuit


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    Figure 7.3 Closed C&S circuit.

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    'RZQWLPH

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    8.Future Research
    This chapter identifies possible developments of the PCCM for other size reduction
    processes such as grinding as well as other sizing processes such as classification.

     PCCM development for other size reduction


    machines
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    8.1.1 Impact crusher/hammer mills


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    8.1.2 Grinding mills


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     PCCM development for other size-sorting machines


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    Appendix G -- Environment, Health, and Safety.
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    Figure G.1 Underground installation of primary crusher and grizzly feeder [75].

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    Figure G.2 Safety helmet, safety shoes/boots, and visible safety west/jacket.

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    Table G. 1 Color on signs in a C&S plant [79].

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    Appendix I -- Analyses of simulation results
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